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NASA NTRS1990

Assembly planning based on subassembly extraction

A method is presented for the automatic determination of assembly partial orders from a liaison graph representation of an assembly through the extraction of preferred subassemblies. In particular, the authors show how to select a set of tentative subassemblies by decomposing a liaison graph into a set of subgraphs based on feasibility and difficulty of disassembly, how to evaluate each of the tentative subassemblies in terms of assembly cost using the subassembly selection indices, and how to construct a hierarchical partial order graph (HPOG) as an assembly plan. The method provides an approach to assembly planning by identifying spatial parallelism in assembly as a means of constructing temporal relationships among assembly operations and solves the problem of finding a cost-effective assembly plan in a flexible environment. A case study of the assembly planning of a mechanical assembly is presented.

Lee, Sukhan↗

NASA NTRS2019

In Space Assembled Telescope (ISAT) Study Preliminary Findings

“When is it advantageous to assemble telescopes in space rather than deploying them from launch vehicle fairings”? This question forms the crux of the objectives of a NASA study we have been conducting in collaboration with colleagues from different NASA centers, industry and academia. In this study, we have engaged a broad cross section of experts from the various fields of optics engineering, that is, telescope design and instrument design, structure and thermal engineering, robotics, launch system engineering, orbital mechanics, integration and testing, astrophysics, and NASA programmatics among others. Initial efforts began with a quick review of the current state of art of the component technologies that contribute towards an in-space assembled telescope. Then, leveraging the collective expertise of the diverse group of experts, we formulated a reference telescope design and attempted to develop a baseline approach to modularize the telescope into components amenable for robotic assembly. The group identified different trades associated with modularization and also developed a set of criteria to discern between the different options as revealed by the trades. Based on the modularization of the telescope, we will assess the impact of various launch vehicles, orbits for assembly and operation, robotic systems and operational approaches, and other related variables. From this, a concept to assemble the reference telescope in space from modular components will be developed. Based on this concept, and definition of the modules, we will develop a mission lifecycle plan for an assembled telescope over different phases of preliminary design, detailed design, assembly-test-and-integration, and in space operations. The mission lifecycle plan will be used to evaluate cost and risk implications of in-space assembly toward answering our fundamental question of the advantages, if any, of assembling a telescope in space as compared to self-deployment. In this paper, we summarize the objectives of the study, a review of the status of the underlying component technologies, a description of the methodology, including three different multi-day technical interchange meetings (TIMs), summary of findings from the TIMs and other related activities. In addition, a detailed description of the various factors that impact in-space assembly, their interplay and criteria for discerning among them, a preliminary description of the life cycle plan, including the test and integration plan, and initial observations on cost and risk implications will be included in the paper.

Mukherjee, Rudranarayan↗

DOE OSTI2025

Lyotropic Liquid Crystal Mediated Assembly of Donor Polymers Enhances Efficiency and Stability of Blade-Coated Organic Solar Cells

Conjugated polymers can undergo complex, concentration-dependent self-assembly during solution processing, yet little is known about its impact on film morphology and device performance of organic solar cells. Herein, lyotropic liquid crystal (LLC) mediated assembly across multiple conjugated polymers is reported, which generally gives rise to improved device performance of blade-coated non-fullerene bulk heterojunction solar cells. Using D18 as a model system, the formation mechanism of LLC is unveiled employing solution X-ray scattering and microscopic imaging tools: D18 first aggregates into semicrystalline nanofibers, then assemble into achiral nematic LLC which goes through symmetry breaking to yield a chiral twist-bent LLC. The assembly pathway is driven by increasing solution concentration – a common driving force during evaporative assembly relevant to scalable manufacturing. This assembly pathway can be largely modulated by coating regimes to give 1) lyotropic liquid crystalline assembly in the evaporation regime and 2) random fiber aggregation pathway in the Landau–Levich regime. The chiral liquid crystalline assembly pathway resulted in films with crystallinity 2.63 times that of films from the random fiber aggregation pathway, significantly enhancing the T80 lifetime by 50-fold. The generality of LLC-mediated assembly and enhanced device performance is further validated using polythiophene and quinoxaline-based donor polymers.

14 SOLAR ENERGY↗

DOE OSTI2025

Efficient analysis of small-angle scattering curves for large biomolecular assemblies using Monte Carlo methods

Structure elucidation from small-angle scattering curves of large biomolecular assemblies is notoriously challenging. This is because the simulation of high-resolution features in the structure of large macromolecular assemblies, such as de novo protein assemblies, is computationally demanding when it needs to cover a broad range of length scales. Conventional methods, such as the numerical approximation to the Debye equation or the use of spherical harmonics, do not scale well as the size of the assembly increases, which limits their application to small structures (e.g. individual proteins). This work explores the effectiveness of a Monte Carlo method to simulate and fit scattering curves for large biomolecular assemblies spanning over ranges covering atomic and molecular detail (e.g. spacing and orientation of proteins in an assembly) as well as large-scale (hundreds of nanometres) features. Owing to its speed and scalability, it can be combined with a fitting algorithm to extract structural features from experimental small-angle scattering curves in biomolecular assemblies that are otherwise intractable for interpretation. This work first demonstrates the effectiveness of the tool using experimental small-angle X-ray scattering (SAXS) data from tile-like proteins that assemble into 1D tube-like macromolecular structures. Here, the diameter distribution of tubes is extracted from SAXS fits, and this is quantitatively compared with distributions from electron microscopy. SAXS data are also obtained from 2D sheet-like protein assemblies, and the proposed method is used to quantify structural features such as the separation distance between protein building blocks and the flexing of the sheet. An open-source implementation of the methodology is provided for use in a broad range of biological systems involving multi-scale scattering analysis.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗

DOE OSTI2025

Cooperative Role of Mixed Solvent in the Evaporation-Induced Self-Assembly of Polypeptoid Nanocrystals

Peptoids, or polypeptoids, are biomimetic polymers that can self-assemble into nanocrystals for biomedical and biotechnological applications. Polypeptoid nanocrystals can be prepared by evaporation-induced self-assembly, but the roles of solvent components for this process have long been overlooked at the molecular level, leaving a tunable parameter for improving self-assembly protocols. This work utilized molecular dynamics simulations to study the effects of water and the commonly used tetrahydrofuran (THF) on the assembly of nanosheets from molecules of acetylated diblock polypeptoid, poly-(N-decylglycine)-b-poly-(N-2-(2-(2-methoxyethoxy)-ethoxy) ethylglycine), abbreviated as Ac-Ndc10-Nte10. To probe the stages of self-assembly, isolated molecules and preassembled nanofibers/nanosheets were simulated in pure THF, water, and their mixtures, respectively. The assembly energies show that the THF/water mixture has a greater tendency to form nanosheets than pure water. In a THF/water mixture, polypeptoids were found more uncoiled in isolated states, less compact in disordered agglomerates, and with reduced requirement for the Nte block to cover hydrophobic Ndc surfaces in the nanocrystals. Mixed solvent is vital to initiating self-assembly, as THF assists in the opening of coiled polypeptoid molecules, while water provides the thermodynamics to aggregate and ultimately form nanocrystals. To obtain wider nanosheets, it is recommended that some THF be maintained in the aqueous solvent before it becomes exhausted by evaporation. Near the nanosheet surface, the THF concentration is higher than that in bulk solution (3-4 times in 4 M THF/water). The strong adsorption of THF indicates the self-assembly in a de facto mixed solvent. These results are expected to guide the refinement of evaporation-induced self-assembly protocols for polypeptoid nanocrystals.

Luo, Xubo↗

NASA NTRS1983

A mobile work station concept for mechanically aided astronaut assembly of large space trusses

This report presents results of a series of truss assembly tests conducted to evaluate a mobile work station concept intended to mechanically assist astronaut manual assembly of erectable space trusses. The tests involved assembly of a tetrahedral truss beam by a pair of test subjects with and without pressure (space) suits, both in Earth gravity and in simulated zero gravity (neutral buoyancy in water). The beam was assembled from 38 identical graphite-epoxy nestable struts, 5.4 m in length with aluminum quick-attachment structural joints. Struts and joints were designed to closely simulate flight hardware. The assembled beam was approximately 16.5 m long and 4.5 m on each of the four sides of its diamond-shaped cross section. The results show that average in-space assembly rates of approximately 38 seconds per strut can be expected for struts of comparable size. This result is virtually independent of the overall size of the structure being assembled. The mobile work station concept would improve astronaut efficiency for on-orbit manual assembly of truss structures, and also this assembly-line method is highly competitive with other construction methods being considered for large space structures.

Heard, W. L., Jr.↗

NASA NTRS1989

A definition study of the on-orbit assembly operations for the outboard photovoltaic power modules for Space Station Freedom

A concept is described for the assembly of the outboard PV modules for Space Station Freedom. Analysis of the on-orbit assembly operations was performed using CADAM design graphics software. A scenario for assembly using the various assembly equipment, as currently defined, is described in words, tables and illustrations. This work is part of ongoing studies in the area of space station assembly. The outboard PV module and the assembly equipment programs are all in definition and preliminary design phases. An input is provided to the design process of assembly equipment programs. It is established that the outboard PV module assembly operations can be performed using the assembly equipment currently planned in the Space Station Freedom Program.

Sours, Thomas J.↗

NASA NTRS1994

Free-floating dual-arm robots for space assembly

Freely moving systems in space conserve linear and angular momentum. As moving systems collide, the velocities get altered due to transfer of momentum. The development of strategies for assembly in a free-floating work environment requires a good understanding of primitives such as self motion of the robot, propulsion of the robot due to onboard thrusters, docking of the robot, retrieval of an object from a collection of objects, and release of an object in an object pool. The analytics of such assemblies involve not only kinematics and rigid body dynamics but also collision and impact dynamics of multibody systems. In an effort to understand such assemblies in zero gravity space environment, we are currently developing at Ohio University a free-floating assembly facility with a dual-arm planar robot equipped with thrusters, a free-floating material table, and a free-floating assembly table. The objective is to pick up workpieces from the material table and combine them into prespecified assemblies. This paper presents analytical models of assembly primitives and strategies for overall assembly. A computer simulation of an assembly is developed using the analytical models. The experiment facility will be used to verify the theoretical predictions.

Agrawal, Sunil Kumar↗

NASA NTRS2005

Autonomous Assembly of Modular Structures in Space and on Extraterrestrial Locations

The new U.S. National Vision for Space Exploration requires many new enabling technologies to accomplish the goals of space commercialization and returning humans to the moon and extraterrestrial environments. Traditionally, flight elements are complete subsystems requiring humans to complete the integration and assembly. These bulky structures also require the use of heavy launch vehicles to send the units to a desired location. This philosophy necessitates a high degree of safety, numerous space walks at a significant cost. Future space mission costs must be reduced and safety increased to reasonably achieve exploration goals. One proposed concept is the autonomous assembly of space structures. This concept is an affordable, reliable solution to in-space and extraterrestrial assembly. Assembly is autonomously performed when two components join after determining that specifications are correct. Local sensors continue monitor joint integrity post assembly, which is critical for safety and structural reliability. Achieving this concept requires a change in space structure design philosophy and the development of innovative technologies to perform autonomous assembly. Assembly of large space structures will require significant numbers of integrity sensors. Thus simple, low-cost sensors are integral to the success of this concept. This paper addresses these issues and proposes a novel concept for assembling space structures autonomously. Core technologies required to achieve in space assembly are presented. These core technologies are critical to the goal of utilizing space in a cost efficient and safe manner. Additionally, these novel technologies can be applied to other systems both on earth and extraterrestrial environments.

Alhorn, Dean C.↗

NASA NTRS2006

Framework for Defining and Assessing Benefits of a Modular Assembly Design Approach for Exploration Systems

A comprehensive modular assembly system model has been proposed that extends the art from modular hardware, to include in-space assembly, servicing and repair and it s critical components of infrastructure, agents and assembly operations. Benefits of modular assembly have been identified and a set of metrics defined that extends the art beyond the traditional measures of performance, with emphasis on criteria that allow life-cycle mission costs to be used as a figure of merit (and include all substantive terms that have an impact on the evaluation). The modular assembly approach was used as a basis for developing a Solar Electric Transfer Vehicle (SETV) concept and three modular assembly scenarios were developed. The modular assembly approach also allows the SETV to be entered into service much earlier than competing conventional configurations and results in a great deal of versatility in accommodating different launch vehicle payload capabilities, allowing for modules to be pre-assembled before launch or assembled on orbit, without changing the space vehicle design.

Dorsey, John T.↗

NASA NTRSDate not supplied

Prism Assembly for Roman Space Telescope Wide Field Instrument Slit-less Spectroscopy

The Roman Space Telescope (RST) is a three mirror anastigmat design with a 2.4 m primary mirror. RST will be based in L2 orbit, from where it will provide science information on exoplanets and dark energy using the Coronagraph Instrument (CGI) and Wide Field Instrument (WFI). The WFI features a 300 megapixel near-infrared detector array which provides a field of view 100 times larger than that of Hubble Space Telescope. The Prism Assembly is a small add-on instrument to the Roman Space Telescope’s Wide Field Instrument (WFI), installed in a slot in WFI’s element wheel. The Prism assembly has a passband from 0.75 µm to 1.8 µm, enabling a survey of redshifts in the range 0.2 to 1.7 µm. It provides low resolution slit-less spectroscopy with a spectral resolution R > 70 for all wavelengths, and R < 170 for λ > 0.8 µm across the full field. The Prism Assembly has the potential to provide more supernova spectra than ground-based spectroscopy during the mission lifetime. Being a late add-on to the RST mission, the Prism Assembly has had restrictions on size, weight and geometry, and a challenging schedule, which has dictated much of the implementation. Despite these challenges, the Prism Assembly is a pocket-sized high-performance spectrographic element, implemented as a refractive, all-spherical optical design using only two elements, one S-TIH-1 glass and one CaF2. This presentation will give an overview of the Prism Assembly, from design and implementation, through alignment, test and calibration. (100 words): The Roman Space Telescope is a three mirror anastigmat design with a 2.4 m primary mirror, which will provide science information on dark energy and exoplanets. The Prism Assembly is a small add-on instrument to the telescope’s Wide Field Instrument, enabling low resolution slit-less spectroscopy with a spectral resolution 70 < R < 170 across the full field from λ= 0.75 µm to 1.8 µm. The Prism Assembly is a refractive, all-spherical optical design using a glass and a CaF2 element. This presentation will give an overview of the Prism Assembly, from design and implementation, through alignment, test and calibration.

Space Instrumentation↗

NASA NTRSDate not supplied

Precision in Assembled Discrete Lattice Space Structures for Next-Generation ISAM Applications

Robust autonomous robotic assembly of large-scale space structures has been a long-term and challenging goal to enable higher quality in-space communication and science instrumentation. For optical observatory support structures and antenna structures, the challenge is the strict dimensional precision requirements (generally RMS surface error) driven by the operational radiation wavelength. Early theoretical work in the area linked RMS surface error of a reflector support truss plate to the natural passive dynamic mode frequencies of the structure, as well as to the error distribution in dimensions of constituent structural elements. Prior robotic truss assembly demonstrations focused on designing ultra-high precision structural elements, joints, and robotic actuators. Recently, an alternative space structure assembly strategy based on a programmable matter approach (NASA ARMADAS) was demonstrated. This approach uses lattice building blocks (voxels) that are reversibly, mechanically joined into a bulk lattice structure by robots that locomote in and on the structure itself. Such a system can achieve high-level autonomy with low computation, robustly assemble utilizing inexpensive and imprecise robots, and efficiently build structures several orders of magnitude larger than the assembly robots. However, for instrumentation support structure applications, the resulting precision of these building block-based lattice structures is not well studied. Since they are demonstrated with many more assembly units than prior art trusses, it is unclear whether the same precision design approaches apply. In this work, we study in simulation the effects of voxel geometry, error in distribution, assembly resolution (module size), and assembly geometry on the error of both beam and plate lattice structures. While average RMS error of a plate increases with plate size, increasing plate thickness quickly collapses RMS error towards a limit that is on the order of the error of the constituent parts. We validate our models against previously published precision measurements of built systems. Results from this study will guide manufacturing precision requirements, as well as designs, for future robotically assembled structural applications and establish feasibility for different applications.

Christine E Gregg↗

NASA NTRSDate not supplied

In-Space Modular Assembly: An Approach for Reliable, Affordable, Precision Space Apertures

In-space assembly will revolutionize the creation, upgrade, and evolution of future space systems. In-space assembly represents an alternative deployment strategy that is not constrained by the requirement of using a single launch vehicle and enables a greater freedom of design for the initial emplacement of assets and their evolution over time. In-space assembly enables assets, such as observatories and science platforms, to become persistent, evolving over time like their terrestrial counterparts. Also, in-space assembly provides a direct path for utilization of in-space manufactured components designed exclusively for the operational environment. To highlight the advantages of an in-space assembly approach, the modular assembly of a 3 m to 4 m precision optical aperture based on thin meniscus technology coupled with structurally efficient TriTruss modules is presented. The 3 m to 4 m aperture stows compactly within two standard ride share slots (0.61 m by 0.71 m by 0.97 m). Placing instruments and the robotic system used for assembly in an adjacent ride share slot enables a capable observatory to be placed into service via modest ride share opportunities. Further, recent hardware assembly tests of similar modules and progress toward hardware tests to validate the overall architecture via diffraction limited testing will be summarized.

Design↗

NASA NTRSDate not supplied

In-Space Modular Assembly: An Approach for Reliable, Affordable, Precision Space Apertures

Design↗

DOE OSTI2024

Assembly, comparative analysis, and utilization of a single haplotype reference genome for soybean

Cultivar Williams 82 has served as the reference genome for the soybean research community since 2008, but is known to have areas of genomic heterogeneity among different sub-lines. This work provides an updated assembly (version Wm82.a6) derived from a specific sub-line known as Wm82-ISU-01 (seeds available under USDA accession PI 704477). The genome was assembled using Pacific BioSciences HiFi reads and integrated into chromosomes using HiC. The 20 soybean chromosomes assembled into a genome of 1.01Gb, consisting of 36 contigs. The genome annotation identified 48 387 gene models, named in accordance with previous assembly versions Wm82.a2 and Wm82.a4. Comparisons of Wm82.a6 with other near-gapless assemblies of Williams 82 reveal large regions of genomic heterogeneity, including regions of differential introgression from the cultivar Kingwa within approximately 30 Mb and 25 Mb segments on chromosomes 03 and 07, respectively. Additionally, our analysis revealed a previously unknown large (> 20 Mb) heterogeneous region in the pericentromeric region of chromosome 12, where Wm82.a6 matches the ‘Williams’ haplotype while the other two near-gapless assemblies do not match the haplotype of either parent of Williams 82. In addition to the Wm82.a6 assembly, we also assembled the genome of ‘Fiskeby III,’ a rich resource for abiotic stress resistance genes. A genome comparison of Wm82.a6 with Fiskeby III revealed the nucleotide and structural polymorphisms between the two genomes within a QTL region for iron deficiency chlorosis resistance. The Wm82.a6 and Fiskeby III genomes described here will enhance comparative and functional genomics capacities and applications in the soybean community.

59 BASIC BIOLOGICAL SCIENCES↗

NASA NTRS1980

Space assembly fixtures and aids

Concepts and requirements for assembly fixtures and aids necessary for the assembly and maintenance of spare platforms were studied. Emphasis was placed on erectable and deployable type structures with the shuttle orbiter as the assembly base. Both single and multiple orbiter flight cases for the platform assembly were considered. Applicable space platform assembly studies were reviewed to provide a data base for establishing the assembly fixture and aids design requirements, assembly constraints, and the development of representative design concepts. Conclusions indicated that fixture requirements will vary with platform size. Larger platforms will require translation relative to the orbiter RMS working volume. The installation of platform payloads and subsystems (e.g., utility distribution) must also be considered in the specification of assembly fixtures and aids.

Bloom, K. A.↗

NASA NTRS1982

Structural assembly demonstration experiment

The experiment is of an operational variety, designed to assess crew capability in Large Space System (LSS) assembly. The six Structural Assembly Demonstration Experiment objectives include: (1) the establishment of a quantitative correlation between LSS neutral buoyancy simulation and on-orbit assembly operations in order to enhance the validity of those assembly simulations; (2) the quantitative study of the capabilities and mechanics of human assembly in an Extravehicular Activity environment; (3) the further corroboration of the LSS Assembly Analysis cost algorithm through the obtainment of hard data base information; (4) the verification of LSS assembly techniques and timeless, as well as the identification of crew imposed loads and assembly aid requirements and concepts; (5) verification of a Launch/Assembly Platform structure concept for other LSS missions; and (6) lastly, to advance thermal control concepts through a flexible heat pipe.

Stokes, J. W.↗

NASA NTRS1992

Tests of an alternate mobile transporter and extravehicular activity assembly procedure for the Space Station Freedom truss

Results are presented from a ground test program of an alternate mobile transporter (MT) concept and extravehicular activity (EVA) assembly procedure for the Space Station Freedom (SSF) truss keel. A three-bay orthogonal tetrahedral truss beam consisting of 44 2-in-diameter struts and 16 nodes was assembled repeatedly in neutral buoyancy by pairs of pressure-suited test subjects working from astronaut positioning devices (APD's) on the MT. The truss bays were cubic with edges 15 ft long. All the truss joint hardware was found to be EVA compatible. The average unit assembly time for a single pair of experienced test subjects was 27.6 sec/strut, which is about half the time derived from other SSF truss assembly tests. A concept for integration of utility trays during truss assembly is introduced and demonstrated in the assembly tests. The concept, which requires minimal EVA handling of the trays, is shown to have little impact on overall assembly time. The results of these tests indicate that by using an MT equipped with APD's, rapid EVA assembly of a space station-size truss structure can be expected.

Heard, Walter L., Jr.↗