Engineering topics

Dorsey, John T.

Publications and source records attributed to Dorsey, John T..

At least 19 records

NASA NTRS2019

Persistent Assets in Zero-G and on Planetary Surfaces: Enabled by Modular Technology and Robotic Operations

Space operations are on the cusp of a revolutionary new operational paradigm that leverages modular systems and recurring robotic visits to “Persistent Assets” enabling asset maintenance, repair, and enhancement. A “Persistent Asset” is defined here as any zero-g or planetary surface system that benefits from in-space assembly (ISA) or multiple visits for servicing, repairs, and upgrades. This term is an extension of the term “Persistent Platform” used by Ms. Pam Melroy at the Defense Advanced Research Projects Agency to describe the vision of the Agency for a geosynchronous Earth orbiting platform. In this paper, the term “Persistent Asset” is introduced to encompass not only zero-g systems; such as telecommunication platforms, Earth observing science platform, Department of Defense platforms, and scientific telescope systems, but also planetary surface systems that support missions such as human outposts, science stations, and in-situ resource utilization systems. In contrast to the current state of the art, where space systems are typically launched as a single unit and operated without any further physical intervention after launch; future systems will be maintained, enhanced and reconfigured in-situ as new technology becomes available or mission needs change. Visits to the persistent asset can be regularly scheduled or dictated by funding constraints enabling a pay-as-you-go approach, which is largely independent of time-constraints and able to exploit launches of opportunity. In this paper, historical in-space assembly activities which relied heavily on astronaut extra-vehicular activity will be reviewed as well as early robotic assembly activities. These approaches will be contrasted with emerging modular approaches supporting realization of a new Persistent Asset operational paradigm. The paper will define attributes of the Persistent Asset paradigm and illustrate advantages by applying the paradigm to two relevant applications: 1) a large space telescope backing structure and 2) the backbone structure for a solar electric transport vehicle. Finally, recently developed unique Persistent Asset elements (modules, and interface approaches) will be described.

Doggett, William R.↗

NASA NTRS2019

Hinge for Use in a Tension Stiffened and Tendon Actuated Manipulator

A tension stiffened and tendon actuated manipulator is provided performing robotic-like movements when acquiring a payload. The manipulator design can be adapted for use in-space, lunar or other planetary installations as it is readily configurable for acquiring and precisely manipulating a payload in both a zero-g environment and in an environment with a gravity field. The manipulator includes a plurality of link arms, a hinge connecting adjacent link arms together to allow the adjacent link arms to rotate relative to each other and a cable actuation and tensioning system provided between adjacent link arms. The cable actuation and tensioning system includes a spreader arm and a plurality of driven and non-driven elements attached to the link arms and the spreader arm. At least one cable is routed around the driven and non-driven elements for actuating the hinge.

Doggett, William R.↗

NASA NTRS2017

Initial Validation of Robotic Operations for In-Space Assembly of a Large Solar Electric Propulsion Transport Vehicle

Developing a capability for the assembly of large space structures has the potential to increase the capabilities and performance of future space missions and spacecraft while reducing their cost. One such application is a megawatt-class solar electric propulsion (SEP) tug, representing a critical transportation ability for the NASA lunar, Mars, and solar system exploration missions. A series of robotic assembly experiments were recently completed at Langley Research Center (LaRC) that demonstrate most of the assembly steps for the SEP tug concept. The assembly experiments used a core set of robotic capabilities: long-reach manipulation and dexterous manipulation. This paper describes cross-cutting capabilities and technologies for in-space assembly (ISA), applies the ISA approach to a SEP tug, describes the design and development of two assembly demonstration concepts, and summarizes results of two sets of assembly experiments that validate the SEP tug assembly steps.

Komendera, Erik E.↗

NASA NTRS2016

Commercial Application of In-Space Assembly

In-Space assembly (ISA) expands the opportunities for cost effective emplacement of systems in space. Currently, spacecraft are launched into space and deploy into their operational configuration through a carefully choreographed sequence of operations. The deployment operation dictates the arrangement of the primary systems on the spacecraft, limiting the ability to take full advantage of launch vehicles volume and mass capability. ISA enables vastly different spacecraft architectures and emplacement scenarios to be achieved, including optimal launch configurations ranging from single launch and assembly to on-orbit aggregation of multiple launches at different orbital locations and times. The spacecraft can be visited at different orbital locations and times to effect expansion and maintenance of an operational capability. To date, the primary application of ISA has been in large programs funded by government organizations, such as the International Space Station. Recently, Space Systems Loral (SSL) led a study funded by the Defense Advanced Research Projects Agency (DARPA), called Dragonfly, to investigate the commercial applicability and economic advantages of ISA. In the study, it was shown that ISA enables SSL to double the capability of a commercial satellite system by taking advantage of alternate packaging approaches for the reflectors. The study included an ultra-light-weight robotic system, derived from Mars manipulator designs, to complete assembly of portions of the antenna system using a tool derived from DARPA orbital express and National Aeronautics and Space Administration (NASA) automated structural assembly experience. The mechanical connector that enables robotic ISA takes advantage of decades of development by NASA from the 1970's to 1980's during the Space Station Freedom program, the precursor to the ISS. The mechanical connector was originally designed for rapid astronaut assembly while also providing a high quality structural connection with linear load deflection response. The paper will discuss the business case for ISA, the general approach taken to exploit on-orbit assembly in the GEO communication satellite market, and the concept of operations associated with the ISA approach, thus laying the foundation for ISA to become an accepted operational approach for commercial in-space operations.

Lymer, John↗

NASA NTRS2016

Space Assembly of Large Structural System Architectures (SALSSA)

Developing a robust capability for Space Assembly of Large Spacecraft Structural System Architectures (SALSSA) has the potential to drastically increase the capabilities and performance of future space missions and spacecraft while significantly reducing their cost. Currently, NASA architecture studies and space science decadal surveys identify new missions that would benefit from SALSSA capabilities, and the technologies that support SALSSA are interspersed throughout the fourteen NASA Technology Roadmaps. However, a major impediment to the strategic development of cross-cutting SALSSA technologies is the lack of an integrated and comprehensive compilation of the necessary information. This paper summarizes the results of a small study that used an integrated approach to formulate a SALSSA roadmap and associated plan for developing key SALSSA technologies.

Dorsey, John T.↗

NASA NTRS2016

Summary of LaRC 2-inch Erectable Joint Hardware Heritage Test Data

As the National Space Transportation System (STS, also known as the Space Shuttle) went into service during the early 1980's, NASA envisioned many missions of exploration and discovery that could take advantage of the STS capabilities. These missions included: large orbiting space stations, large space science telescopes and large spacecraft for manned missions to the Moon and Mars. The missions required structures that were significantly larger than the payload volume available on the STS. NASA Langley Research Center (LaRC) conducted studies to design and develop the technology needed to assemble the large space structures in orbit. LaRC focused on technology for erectable truss structures, in particular, the joint that connects the truss struts at the truss nodes. When the NASA research in large erectable space structures ended in the early 1990's, a significant amount of structural testing had been performed on the LaRC 2-inch erectable joint that was never published. An extensive set of historical information and data has been reviewed and the joint structural testing results from this historical data are compiled and summarized in this report.

Dorsey, John T.↗

NASA NTRS2016

In-Space Structural Assembly: Applications and Technology

As NASA exploration moves beyond earth's orbit, the need exists for long duration space systems that are resilient to events that compromise safety and performance. Fortunately, technology advances in autonomy, robotic manipulators, and modular plug-and-play architectures over the past two decades have made in-space vehicle assembly and servicing possible at acceptable cost and risk. This study evaluates future space systems needed to support scientific observatories and human/robotic Mars exploration to assess key structural design considerations. The impact of in-space assembly is discussed to identify gaps in structural technology and opportunities for new vehicle designs to support NASA's future long duration missions.

Belvin, W. Keith↗

NASA NTRS2015

Tension Stiffened and Tendon Actuated Manipulator

Doggett, William R.↗

NASA NTRS2015

Control System Design Implementation and Preliminary Demonstration for a Tendon-Actuated Lightweight In-Space MANipulator (TALISMAN)

Satellite servicing is a high priority task for NASA and the space industry, addressing the needs of a variety of missions, and potentially lowering the overall cost of missions through refurbishment and reuse. However, the ability to service satellites is severely limited by the lack of long reach manipulation capability and inability to launch new devices due the end of the Space Transport System, or Space Shuttle Program. This paper describes the design and implementation of a control system for a Tendon-Actuated Lightweight In-Space MANipulator (TALISMAN), including; defining the forward and inverse kinematics, endpoint velocity to motor velocity, required cable tensions, and a proportional-integral-derivative (PID) controller. The tensions and velocities necessary to maneuver and capture small and large payloads are also discussed. To demonstrate the utility of the TALISMAN for satellite servicing, this paper also describes a satellite servicing demonstration using two TALISMAN prototypes to grasp and inspect a satellite mockup. Potential avenues for improving the control system are discussed.

Komendera, Erik E.↗

NASA NTRS2015

Structural Sizing Methodology for the Tendon-Actuated Lightweight In-Space MANipulator (TALISMAN) System

The Tendon-Actuated Lightweight In-Space MANipulator (TALISMAN) is a versatile long-reach robotic manipulator that is currently being tested at NASA Langley Research Center. TALISMAN is designed to be highly mass-efficient and multi-mission capable, with applications including asteroid retrieval and manipulation, in-space servicing, and astronaut and payload positioning. The manipulator uses a modular, periodic, tension-compression design that lends itself well to analytical modeling. Given the versatility of application for TALISMAN, a structural sizing methodology was developed that could rapidly assess mass and configuration sensitivities for any specified operating work space, applied loads and mission requirements. This methodology allows the systematic sizing of the key structural members of TALISMAN, which include the truss arm links, the spreaders and the tension elements. This paper summarizes the detailed analytical derivations and methodology that support the structural sizing approach and provides results from some recent TALISMAN designs developed for current and proposed mission architectures.

Jones, Thomas C.↗

NASA NTRS2015

Improvements to the Tendon-Actuated Lightweight In-Space MANipulator (TALISMAN)

Devices for manipulating and precisely placing payloads are critical for efficient space operations including berthing of spacecraft, in-space assembly, construction and repair. Key to the success of many NASA space activities has been the availability of long-reach crane-like devices such as the Shuttle Remote Manipulation System (SRMS) and the Space Station Remote Manipulation System (SSRMS). These devices have been used for many operations including berthing visiting spacecraft to the International Space Station, deployment of spacecraft, space station assembly, astronaut positioning, payload transfer, and spacecraft inspection prior to atmospheric re-entry. Retiring the Space Transportation System has led to the removal of the SRMS from consideration for in-space missions, thus creating a capability gap. Recognizing this gap, work was initiated at NASA on a new architecture for long-reach space manipulators. Most current devices are constructed by joining revolute joints with carbon composite tubes, with the joints accounting for the majority of the device mass. For example in the case of the SRMS, the entire device mass is 410 kg (904 lbm); the joint structure, motors, gear train, cabling, etc., accounts for the majority of the system mass because the carbon composite tubes mass is 46 kg (101 lbm). An alternate space manipulator concept, the Tendon-Actuated Lightweight In-Space MANipulator (TALISMAN) was created to address deficiencies in the current state-of-the-art in long-reach manipulators. The antagonistic tendon actuated joint architecture allows the motors actuating the joint to be removed from the joint axis, which simplifies the joint design while simultaneously providing mechanical advantage for the motors. The improved mechanical advantage, in turn, reduces the size and power requirements for the motor and gear train. This paper will describe recent architectural improvements to the TALISMAN design that: 1) improve the operational robustness of the system by enabling maneuvers not originally possible by varying the TALISMAN geometry; 2) enable efficient active antagonistic control of a joint while sharing cable between antagonistic tension networks; and 3) uses a unique arrangement of differential capstans to reduce motor torque requirements by an order of magnitude. The paper will also summarize recent efforts to enable autonomous deployment of a TALISMAN including the deployment concept of operations and associated hardware system design. The deployment forces are provided by the same motor systems that are used for articulation, thus reducing the mass associated with the deployment system. The deployment approach is being tested on a TALISMAN prototype which is designed to provide the same operational performance as a shuttle-class manipulator. The prototype has been fabricated and is operational in a new facility at NASA Langley Research Center that has a large area (15.2 m by 21.3 m [50 ft by 70 ft]) air-bearing floor.

Doggett, William R.↗

NASA NTRS2015

Tendon-Actuated Lightweight In-Space MANipulator (TALISMAN)

The robotic architecture of State-of-the-Art (SOA) space manipulators, represented by the Shuttle Remote Manipulator System (SRMS), inherently limits their capabilities to extend reach, reduce mass, apply force and package efficiently. TALISMAN uses a new and innovative robotic architecture that incorporates a combination of lightweight truss links, a novel hinge joint, tendon-articulation and passive tension stiffening to achieve revolutionary performance. A TALISMAN with performance similar to the SRMS has 1/10th of its mass and packages in 1/7th of its volume. The TALISMAN architecture allows its reach to be scaled over a large range; from 10 to over 300 meters. In addition, the dexterity (number of degrees-of-freedom) can be easily adjusted without significantly impacting manipulator mass because the joints are very lightweight.

Dorsey, John T.↗

NASA NTRS2015

Application of a Novel Long-Reach Manipulator Concept to Asteroid Redirect Missions

A high priority mission currently being formulated by NASA is to capture all or part of an asteroid and return it to cis-lunar space for examination by an astronaut crew. Two major mission architectures are currently being considered: in the first (Mission Concept A), a spacecraft would rendezvous and capture an entire free flying asteroid (up to 14 meters in diameter), and in the second (Mission Concept B), a spacecraft would rendezvous with a large asteroid (which could include one of the Martian moons) and retrieve a boulder (up to 4 meters in diameter). A critical element of the mission is the system that will capture the asteroid or boulder material, enclose it and secure it for the return flight. This paper describes the design concepts, concept of operations, structural sizing and masses of capture systems that are based on a new and novel Tendon- Actuated Lightweight In-Space MANipulator (TALISMAN) general-purpose robotic system. Features of the TALISMAN system are described and the status of its technology development is summarized. TALISMAN-based asteroid material retrieval system concepts and concepts-of-operations are defined for each asteroid mission architecture. The TALISMAN-based capture systems are shown to dramatically increase operational versatility while reducing mission risk. Total masses of TALISMAN-based systems are presented, reinforcing the mission viability of using a manipulator-based approach for the asteroid redirect mission.

Dorsey, John T.↗

NASA NTRS2014

Development of a Tendon-Actuated Lightweight In-Space MANipulator (TALISMAN)

An invention of a new and novel space robotic manipulator is described. By using a combination of lightweight truss links, a novel hinge joint, tendon-articulation and passive tension stiffening, this new robotic manipulator architecture achieves compact packaging, high strength, stiffness and dexterity while being very lightweight compared to conventional manipulators. The manipulator is also very modular; easy to scale for different reach, load and stiffness requirements; enabling customization for a diverse set of applications. Novel features of the new manipulator concept are described as well as some of the approaches to implement these design features. Two diverse applications are presented to show the versatility of the concept. First generation prototype hardware was designed, manufactured and has been assembled into a working manipulator that is being used to refine and extend development efforts.

Doggett, William R.↗

NASA NTRS2014

Development of a Tendon-Actuated Lightweight In-Space MANipulator (TALISMAN)

Doggett, William R.↗

NASA NTRS2014

Truss Assembly and Welding by Intelligent Precision Jigging Robots

This paper describes an Intelligent Precision Jigging Robot (IPJR) prototype that enables the precise alignment and welding of titanium space telescope optical benches. The IPJR, equipped with micron accuracy sensors and actuators, worked in tandem with a lower precision remote controlled manipulator. The combined system assembled and welded a 2 m truss from stock titanium components. The calibration of the IPJR, and the difference between the predicted and the truss dimensions as-built, identified additional sources of error that should be addressed in the next generation of IPJRs in 2D and 3D.

Komendera, Erik↗

NASA NTRS2014

Precise Truss Assembly Using Commodity Parts and Low Precision Welding

Hardware and software design and system integration for an intelligent precision jigging robot (IPJR), which allows high precision assembly using commodity parts and low-precision bonding, is described. Preliminary 2D experiments that are motivated by the problem of assembling space telescope optical benches and very large manipulators on orbit using inexpensive, stock hardware and low-precision welding are also described. An IPJR is a robot that acts as the precise "jigging", holding parts of a local structure assembly site in place, while an external low precision assembly agent cuts and welds members. The prototype presented in this paper allows an assembly agent (for this prototype, a human using only low precision tools), to assemble a 2D truss made of wooden dowels to a precision on the order of millimeters over a span on the order of meters. The analysis of the assembly error and the results of building a square structure and a ring structure are discussed. Options for future work, to extend the IPJR paradigm to building in 3D structures at micron precision are also summarized.

Komendera, Erik↗

NASA NTRS2014

Habitat Demonstration Unit (HDU) Vertical Cylinder Habitat

NASA's Constellation Architecture Team defined an outpost scenario optimized for intensive mobility that uses small, highly mobile pressurized rovers supported by portable habitat modules that can be carried between locations of interest on the lunar surface. A compact vertical cylinder characterizes the habitat concept, where the large diameter maximizes usable flat floor area optimized for a gravity environment and allows for efficient internal layout. The module was sized to fit into payload fairings for the Constellation Ares V launch vehicle, and optimized for surface transport carried by the All-Terrain Hex-Limbed Extra-Terrestrial Explorer (ATHLETE) mobility system. Launch and other loads are carried through the barrel to a top and bottom truss that interfaces with a structural support unit (SSU). The SSU contains self-leveling feet and docking interfaces for Tri-ATHLETE grasping and heavy lift. A pressurized module needed to be created that was appropriate for the lunar environment, could be easily relocated to new locations, and could be docked together in multiples for expanding pressurized volume in a lunar outpost. It was determined that horizontally oriented pressure vessels did not optimize floor area, which takes advantage of the gravity vector for full use. Hybrid hard-inflatable habitats added an unproven degree of complexity that may eventually be worked out. Other versions of vertically oriented pressure vessels were either too big, bulky, or did not optimize floor area. The purpose of the HDU vertical habitat module is to provide pressurized units that can be docked together in a modular way for lunar outpost pressurized volume expansion, and allow for other vehicles, rovers, and modules to be attached to the outpost to allow for IVA (intra-vehicular activity) transfer between them. The module is a vertically oriented cylinder with a large radius to allow for maximal floor area and use of volume. The modular, 5- m-diameter HDU vertical habitat module consists of a 2-m-high barrel with 0.6-mhigh end domes forming the 56-cubicmeter pressure vessel, and a 19-squaremeter floor area. The module has up to four docking ports located orthogonally from each other around the perimeter, and up to one docking port each on the top or bottom end domes. In addition, the module has mounting trusses top and bottom for equipment, and to allow docking with the ATHLETE mobility system. Novel or unique features of the HDU vertical habitat module include the nodelike function with multiple pressure hatches for docking with other versions of itself and other modules and vehicles; the capacity to be carried by an ATHLETE mobility system; and the ability to attach inflatable 'attic' domes to the top for additional pressurized volume.

Howe, Alan↗