Engineering Papers⌕ Search

SEARCH · Engineering Papers

Results for “modular manufacturing”

Search indexed NASA NTRS and DOE OSTI research on propulsion, heat transfer, battery materials and energy systems. Follow report and document links to the original sources.

Quote a phrase for an exact phrase match. Source license links do not imply unrestricted reuse.

At least 37 records · Page 2
All sourcesNASA NTRSDOE OSTI
NASA NTRS1990

Transformational part-count in layered octahedral-tetrahedral truss configurations

The number of component part (nodes, struts and panels) termed part count, is an important factor in the design, manufacture, and assembly of modular space structures. Part count expressions are presented for a variety of profiles derived from the layered octahedral-tetrahedral truss configuration. Referred to as the tetrahedral truss in the NASA projects, this specific geometry has been used in several missions. The general expressions presented here transforms to others as one profile changes to another. Such transformational part count relations provide a measure of flexibility and generality, and may be useful when dealing with a wider range of geometric configurations.

Lalvani, Haresh↗
NASA NTRS2019

Managing Flagship Missions to Reduce Cost and Schedule

Flagship missions are highly complex with highly nested systems. This level of complexity poses unique management problems as complexity influences risk which, in turn, affects cost and schedule. Establishing a strong technical and programmatic leadership team is critical to mission success. Developing and using a mission architecture is critical to informing the management organization, product ownership, interface and integration relationships, schedule organization, and integration and test paths. In highly nested systems, the mission phasing can be significantly out of sync with product phasing. Targeted technology development prior to Phase A is critical to reducing risk. Early architecture, concept design, and requirements development is critical to reducing risk. Modular design; pathfinders; parallel manufacturing and integration and test paths; and properly handling institutional requirements across interfaces are all management techniques that can be applied to reduce risk. NASA’s large strategic missions, sometimes referred to as flagship missions, are designed to provide answers to some of the most compelling scientific questions being asked. These types of missions are a series of highly nested subsystems that pose unique management problems when compared to more traditional instrument and spacecraft designs. They typically have an overall architecture that is very complex and nested; they typically require a tremendous amount of technology development; they typically involve many contractors and subcontractors with many associated contracts; and they typically involve staff from all over the world. Successful management of a flagship requires the balance between science requirements, engineering and technology capabilities, and resource constraints. Mismanaging these flagship missions can and will lead to significant cost and schedule growth, both of which are detrimental to NASA’s overall reputation which, in turn, is detrimental to the development of future flagship missions. While many of the same management principles used on smaller instruments and spacecraft are relevant, managing flagship missions requires an evolution of those current best practices to better address the specific needs and additional complexity and vastness of these missions. This paper explores how to leverage lessons learned from previous flagship missions to better manage flagship missions in the future.

Hylan, Jason↗
NASA NTRS1989

Development of real-time software environments for NASA's modern telemetry systems

An effort has been made to maintain maximum performance and flexibility for NASA-Goddard's VLSI telemetry system elements through the development of two real-time systems: (1) the Base System Environment, which supports generic system integration and furnishes the basic porting of various manufacturers' cards, and (2) the Modular Environment for Data Systems, which supports application-specific developments and furnishes designers with a set of tested generic library functions that can be employed to speed up the development of such application-specific real-time codes. The performance goals and design rationale for these two systems are discussed.

Horner, Ward↗
NASA NTRS2005

Solid State Digital Propulsion "Cluster Thrusters" For Small Satellites Using High Performance Electrically Controlled Extinguishable Solid Propellants (ECESP)

Electrically controlled extinguishable solid propellants (ESCSP) are capable of multiple ignitions, extinguishments and throttle control by the application of electrical power. Both core and end burning no moving parts ECESP grains/motors to three inches in diameter have now been tested. Ongoing research has led to a newer family of even higher performance ECESP providing up to 10% higher performance, manufacturing ease, and significantly higher electrical conduction. The high conductivity was not found to be desirable for larger motors; however it is ideal for downward scaling to micro and pico- propulsion applications with a web thickness of less than 0.125 inch/ diameter. As a solid solution propellant, this ECESP is molecularly uniform, having no granular structure. Because of this homogeneity and workable viscosity it can be directly cast into thin layers or vacuum cast into complex geometries. Both coaxial and grain stacks have been demonstrated. Combining individual propellant coaxial grains and/or grain stacks together form three-dimensional arrays yield modular cluster thrusters. Adoption of fabless manufacturing methods and standards from the electronics industry will provide custom, highly reproducible micro-propulsion arrays and clusters at low costs. These stack and cluster thruster designs provide a small footprint saving spacecraft surface area for solar panels and/or experiments. The simplicity of these thrusters will enable their broad use on micro-pico satellites for primary propulsion, ACS and formation flying applications. Larger spacecraft may find uses for ECESP thrusters on extended booms, on-orbit refueling, pneumatic actuators, and gas generators.

Sawka, Wayne N.↗
NASA NTRS1993

A module concept for a cable-mesh deployable antenna

This paper describes the design, manufacture, and deployment tests of a modular mesh deployable antenna. Reaction forces and moments created by a mesh and cable network are estimated using CASA. Deployment analysis is carried out using DADS. Three types of deployable antenna modules are developed and fabricated. Their design approach and deployment characteristics are also presented. Ground deployment tests are performed to verify design criteria.

Meguro, Akira↗
NASA NTRS1989

Performance evaluation of automated manufacturing systems using generalized stochastic Petri Nets

The main objective of this research is to develop a generic modeling methodology with a flexible and modular framework to aid in the design and performance evaluation of integrated manufacturing systems using a unified model. After a thorough examination of the available modeling methods, the Petri Net approach was adopted. The concurrent and asynchronous nature of manufacturing systems are easily captured by Petri Net models. Three basic modules were developed: machine, buffer, and Decision Making Unit. The machine and buffer modules are used for modeling transfer lines and production networks. The Decision Making Unit models the functions of a computer node in a complex Decision Making Unit Architecture. The underlying model is a Generalized Stochastic Petri Net (GSPN) that can be used for performance evaluation and structural analysis. GSPN's were chosen because they help manage the complexity of modeling large manufacturing systems. There is no need to enumerate all the possible states of the Markov Chain since they are automatically generated from the GSPN model.

Al-Jaar, Robert Y.↗
NASA NTRS1981

Modular antenna design study

The mechanical design of a modular antenna concept was developed sufficiently to allow manufacture of a working demonstration model of a module, to predict mass properties, and to make performance estimates for antenna reflectors composed of these modules. The primary features of this concept are: (1) each module is an autonomous structural element which can be attached to adjacent modules through a three point connection; (2) the upper surface is a folding hexagonal truss plate mechanism which serves as the supporting structure for a reflective surface; and (3) the entire truss and surface can be folded into a cylindrical envelope in which all truss elements are essentially parallel. The kinematic studies and engineering demonstration model fully verified the deployment kinematics, stowing philosophy, and deployment sequencing for large antenna modules. It was established that such modules can be stowed in packages as small as 25 cm in diameter, using 1.27 cm diameter structural tubes. The development activity indicates that this deployable modular approach towards building large structures in space will support erection of 450 m apertures for operation up to 3 GHz with a single space shuttle flight.

Ribble, J. W.↗
NASA NTRS2007

Performance of the NEXT Engineering Model Power Processing Unit

The NASA s Evolutionary Xenon Thruster (NEXT) project is developing an advanced ion propulsion system for future NASA missions for solar system exploration. An engineering model (EM) power processing unit (PPU) for the NEXT project was designed and fabricated by L-3 Communications under contract with NASA Glenn Research Center (GRC). This modular PPU is capable of processing up from 0.5 to 7.0 kW of output power for the NEXT ion thruster. Its design includes many significant improvements for better performance over the state-of-the-art PPU. The most significant difference is the beam supply which is comprised of six modules and capable of very efficient operation through a wide voltage range because of innovative features like dual controls, module addressing, and a high current mode. The low voltage power supplies are based on elements of the previously validated NASA Solar Electric Propulsion Technology Application Readiness (NSTAR) PPU. The highly modular construction of the PPU resulted in improved manufacturability, simpler scalability, and lower cost. This paper describes the design of the EM PPU and the results of the bench-top performance tests.

Pinero, Luis R.↗
NASA NTRS2001

Metallurgical examination of an AMTEC power unit

Two AMTEC power units fabricated by Advanced Modular Power Systems, Inc. using a cold end condenser manufactured by Creare, Inc. which operate for 342 hours and 575 hours were dissected and examined.

AMTEC↗
NASA NTRS2018

Geometry and Joint Systems for Lattice-Based Reconfigurable Space Structures

We describe analytical methods for the design of the discrete elements of ultralight lattice structures. This modular, building block strategy allows for relatively simple element manufacturing, as well as relatively simple robotic assembly of low mass density structures on orbit, with potential for disassembly and reassembly into highly varying and large structures. This method also results in a structure that is easily navigable by relatively small mobile robots. The geometry of the cell can allow for high packing efficiency to minimize wasted payload volume while maximizing structural performance and constructability. We describe the effect of geometry choices on the final system mechanical properties, manufacturability of the components, and automated robotic constructability of a final system. Geometry choices considered include building block complexity, symmetry of the unit cell, and effects of vertex, edge, and face connectivity of the unit cell. Mechanical properties considered include strength scaling, modulus scaling, and structural performance of the joint, including proof load, shear load, mass, and loading area; as well as validation and verification opportunities. Manufacturability metrics include cost and time, manufacturing method (COTS versus custom), and tolerances required. Automated constructability metrics include local effects of loads imparted to the structure by the robot and assembly complexity, encompassing the ability of the robot to clamp and number of placement motions needed for assembly.

Ochalek, Megan E.↗
NASA NTRS2015

Biomimetic Fly Eye Sensor for Real-Time Target Tracking

The project objective is to design, build, and demonstrate a biomimetic (inspired by biology) smart sensor based on the common house fly eye for real-time target tracking in three dimensions (3-D). The sensor makes use of revolutionary optical sensor design resulting in significantly improved motion detection capabilities when compared with conventional optical sensors. The design is motivated by the parallel nature of the flys vision system and its demonstrated hyperacuity or precision of visual localization beyond the conventional resolution limit. This means that the sensor is able to accurately detect very fast motion and small changes in motion. The analog architecture of the sensor allows for real-time solution at adjustable bandwidths depending on the application. The low cost, exceptionally lightweight, small form factor, low power requirements, and low computation requirements of the sensor make it ideally suited to many aeronautics applications that have limitations on weight, power, and processing time. The sensor is modular and can be easily adapted in scale and manufactured for a wide variety of sensing applications. Advanced target tracking algorithms will be developed to allow the sensor to track a target in 3-D. These algorithms will be implemented in the smart sensors hardware to enable real-time target tracking.

wing position measurement system↗
NASA NTRS2019

Geometry Systems for Lattice-Based Reconfigurable Space Structures

We describe analytical methods for the design of the discrete elements of ultralight lattice structures. This modular, building block strategy allows for relatively simple element manufacturing, as well as relatively simple robotic assembly of low mass density structures on orbit, with potential for disassembly and reassembly into highly varying and large structures. This method also results in a structure that is easily navigable by relatively small mobile robots. The geometry of the cell can allow for high packing efficiency to minimize wasted payload volume while maximizing structural performance and constructability. We describe the effect of geometry choices on the final system mechanical properties and automated robotic constructability of a final system. Geometric properties considered include number of attachments per voxel, number of attachments per coefficient of volume, and effects of vertex, edge, and face connectivity of the unit cell. Mechanical properties considered include strength scaling, modulus scaling, and packing efficiency of the lattice. Automated constructibility metrics include volume allowance for an end-effector, strut clearance angle for an end-effector, and packing efficiency. These metrics were applied to six lattice unit cell geometries: cube, cuboctahedron, octahedron, octet, rhombic dodecahedron, and truncated octahedron. A case study is presented to determine the most suitable lattice system for a specific set of strength and modulus scaling requirements while optimizing for ease of robotic assembly.

lattice geometry↗
NASA NTRSDate not supplied

Geometry Systems for Lattice-Based Reconfigurable Space Structures

We describe analytic methods for the design of the discrete elements of ultralight lattice structures. This modular building block strategy allows for relatively simple element manufacturing as well as relatively simple robotic assembly of low mass-density structures on orbit, with potential for disassembly and reassembly into highly varying and large structures. This method also results in a structure that is easily navigable by relatively small, mobile robots. The geometry of the cell can allow for high packing efficiency to minimize wasted payload volume while maximizing structural performance and constructability. We describe the effect of geometry choices on the mechanical properties and automated robotic constructability of a final system. Geometric properties considered include number of attachments per voxel, number of attachments per coefficient of volume, and effects of vertex, edge, and face connectivity of the unit cell. Mechanical properties considered include strength scaling, modulus scaling, and packing efficiency of the lattice. Automated constructibility metrics include volume allowance for an end-effector, strut clearance angle for an end-effector, and packing efficiency. These metrics were applied to six lattice unit cell geometries: cube, cuboctahedron, octahedron, octet, rhombic dodecahedron, and truncated octahedron. A case study is presented to determine the most suitable lattice system for a specific set of strength and modulus scaling requirements while optimizing for ease of robotic assembly.

digital materials↗
NASA NTRS1971

Modular space station phase B extension integrated ground operations

Requirements for development test, manufacturing, facilities, GSE, training, logistics support, and launch operations are described. The prime integrating requirement is the early establishment of a common data base and its use throughout the design, development, and operational life of the station. The common data base is defined, and the concept of its use is presented. Development requirements for the station modules and subsystems are outlined along with a master development phasing chart.

Selegue, D. F.↗
NASA NTRS2020

Robotic Assembly Activities at NASA Langley Research Center

Over the past several decades, NASA Langley Research Center (LaRC) has developed a suite of hardware and software capabilities for robotic in-space assembly. Specific robots include the Lightweight Surface Manipulation System (LSMS), Tendon-Actuated Lightweight In-Space Manipulator (TALISMAN), NASA Intelligent Jigging and Assembly Robot (NINJAR), Strut Assembly, Manufacturing, Utility & Robotic Aid (SAMURAI), and most recently the Assemblers modular robots. Alongside the hardware, software tools such as the Autonomous Entity Operations Network (AEON) and the Baseline Environment for Autonomous Modeling (BEAM) have been developed to enable communication and simulation respectively. These tools have supported foundational research in single and multi-agent control, sensing and perception, trajectory generation, task allocation, and human-machine teaming. This talk will provide a broad overview of these capabilities and go into detail on recent developments made by the Assemblers project to create modular, reconfigurable robots for autonomous in-space assembly.

John R Cooper↗
NASA NTRS1991

A cost-effective intelligent robotic system with dual-arm dexterous coordination and real-time vision

Dexterous coordination of manipulators based on the use of redundant degrees of freedom, multiple sensors, and built-in robot intelligence represents a critical breakthrough in development of advanced manufacturing technology. A cost-effective approach for achieving this new generation of robotics has been made possible by the unprecedented growth of the latest microcomputer and network systems. The resulting flexible automation offers the opportunity to improve the product quality, increase the reliability of the manufacturing process, and augment the production procedures for optimizing the utilization of the robotic system. Moreover, the Advanced Robotic System (ARS) is modular in design and can be upgraded by closely following technological advancements as they occur in various fields. This approach to manufacturing automation enhances the financial justification and ensures the long-term profitability and most efficient implementation of robotic technology. The new system also addresses a broad spectrum of manufacturing demand and has the potential to address both complex jobs as well as highly labor-intensive tasks. The ARS prototype employs the decomposed optimization technique in spatial planning. This technique is implemented to the framework of the sensor-actuator network to establish the general-purpose geometric reasoning system. The development computer system is a multiple microcomputer network system, which provides the architecture for executing the modular network computing algorithms. The knowledge-based approach used in both the robot vision subsystem and the manipulation control subsystems results in the real-time image processing vision-based capability. The vision-based task environment analysis capability and the responsive motion capability are under the command of the local intelligence centers. An array of ultrasonic, proximity, and optoelectronic sensors is used for path planning. The ARS currently has 18 degrees of freedom made up by two articulated arms, one movable robot head, and two charged coupled device (CCD) cameras for producing the stereoscopic views, and articulated cylindrical-type lower body, and an optional mobile base. A functional prototype is demonstrated.

Marzwell, Neville I.↗
NASA NTRS2004

Teleoperated Modular Robots for Lunar Operations

Solar system exploration is currently carried out by special purpose robots exquisitely designed for the anticipated tasks. However, all contingencies for in situ resource utilization (ISRU), human habitat preparation, and exploration will be difficult to anticipate. Furthermore, developing the necessary special purpose mechanisms for deployment and other capabilities is difficult and error prone. For example, the Galileo high gain antenna never opened, severely restricting the quantity of data returned by the spacecraft. Also, deployment hardware is used only once. To address these problems, we are developing teleoperated modular robots for lunar missions, including operations in transit from Earth. Teleoperation of lunar systems from Earth involves a three second speed-of-light delay, but experiment suggests that interactive operations are feasible.' Modular robots typically consist of many identical modules that pass power and data between them and can be reconfigured for different tasks providing great flexibility, inherent redundancy and graceful degradation as modules fail. Our design features a number of different hub, link, and joint modules to simplify the individual modules, lower structure cost, and provide specialized capabilities. Modular robots are well suited for space applications because of their extreme flexibility, inherent redundancy, high-density packing, and opportunities for mass production. Simple structural modules can be manufactured from lunar regolith in situ using molds or directed solar sintering. Software to direct and control modular robots is difficult to develop. We have used genetic algorithms to evolve both the morphology and control system for walking modular robots3 We are currently using evolvable system technology to evolve controllers for modular robots in the ISS glove box. Development of lunar modular robots will require software and physical simulators, including regolith simulation, to enable design and test of robot software and hardware, particularly automation software. Ready access to these simulators could provide opportunities for contest-driven development ala RoboCup (http://www.robocup.org/). Licensing of module designs could provide opportunities in the toy market and for spin-off applications.

Globus, Al↗