DTC for Bidirectional Power Exchange (DTC PWRX-TASK)

Maintaining reliable electrical connectivity in dusty environments presents a significant challenge for lunar surface operations. Terrestrial connectors have long been designed to tolerate high levels of contamination, often utilizing high normal forces and wiping actions to remove debris during mating cycles. These design principles are now being adapted for space-rated connectors, where the abrasive and adhesive nature of lunar regolith introduces unique risks to connector performance, durability, and mission success. Preliminary testing conducted at the Simulant Development Lab has yielded promising results using commercially available connectors. Though originally intended for terrestrial applications, these connectors demonstrated encouraging tolerance to simulated lunar dust conditions. Building on these findings, the current effort focuses on identifying and procuring bidirectional power connectors that meet the expected electrical and mechanical requirements for lunar missions. Candidate connectors will undergo rigorous testing with lunar regolith simulants to evaluate their dust tolerance, electrical integrity, and mechanical reliability. A key component of this testing campaign is the development of the vacuum-rated Uniform Dust Deposition System (UDDS). This system features a mechanical and electrical fixture that uniformly applies lunar regolith simulants to connector interfaces. It then performs automated mate/demate cycling while collecting performance data to assess degradation due to dust exposure. The latest iteration of the UDDS includes upgrades that enable testing within a thermal-vacuum chamber, providing a more representative lunar environment. This technology development effort supports the advancement of robust connector solutions for lunar surface systems and contributes to broader dust mitigation strategies essential for sustained human and robotic exploration beyond Earth.

​The vacuum-rated Uniform Dust Deposition System (UDDS V2.0) delivers a vital capability for advancing lunar surface power systems by enabling standardized, repeatable testing of electrical connectors exposed to simulated regolith environments. This system directly supports closing critical gaps in the Extravehicular Activity and Human Surface Mobility (EHP) Lunar Surface Integration Phase Power Specification, EHP-10069, by offering NASA a method to define and evaluate “dust tolerance” criteria for connectors intended for lunar deployment.Once a recommended test protocol is established, UDDS V2.0 will be used to assess connector contact performance. Its configurable architecture allows for testing across a wide range of parameters, including environmental conditions (e.g., vacuum and temperature), voltage and current, regolith types (lunar or Martian simulants), connector geometries, and varying mate/demate cycles. This flexibility ensures adaptability to diverse customer needs and mission-specific requirements. Future expansions of UDDS capabilities may include testing beyond electrical connectors, such as electronic components or small mechanical assemblies. By enabling testing in representative lunar environments, UDDS V2.0 provides critical insights into dust-induced degradation over time, helping hardware designers understand long-term impacts and improve system reliability. These insights are essential for developing robust, dust-tolerant electrical interfaces that support sustained human and robotic operations on planetary surfaces.

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