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All sourcesNASA NTRSDOE OSTI
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 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.↗
NASA NTRS1994

Special test equipment and fixturing for MSAT reflector assembly alignment

The MSAT Reflector Assembly is a state of the art subsystem for Mobile Satellite (MSAT), a geosynchronous-based commercial mobile telecommunication satellite program serving North America. The Reflector Assembly consisted of a deployable, three-hinge, folding-segment Boom, deployable 5.7 x 5.3-meter 16-rib Wrap-Rib Reflector, and a Reflector Pointing Mechanism (RPM). The MSAT spacecraft was based on a Hughes HS601 spacecraft bus carrying two Reflector Assemblies independently dedicated for L-band transmit and receive operations. Lockheed Missiles and Space Company (LMSC) designed and built the Reflector Assembly for MSAT under contract to SPAR Aerospace Ltd. Two MSAT satellites were built jointly by SPAR Aerospace Ltd. and Hughes Space and Communications Co. for this program, the first scheduled for launch in 1994. When scaled for wavelength, the assembly and alignment requirements for the Reflector Assembly were in many instances equivalent to or exceeded that of a diffraction-limited visible light optical system. Combined with logistical constraints inherent to large, compliant, lightweight structures; 'bolt-on' alignment; and remote, indirect spacecraft access; the technical challenges were formidable. This document describes the alignment methods, the special test equipment, and fixturing for Reflector Assembly assembly and alignment.

Young, Jeffrey A.↗
NASA NTRS1989

SSME component assembly and life management expert system

The space shuttle utilizes several rocket engine systems, all of which must function with a high degree of reliability for successful mission completion. The space shuttle main engine (SSME) is by far the most complex of the rocket engine systems and is designed to be reusable. The reusability of spacecraft systems introduces many problems related to testing, reliability, and logistics. Components must be assembled from parts inventories in a manner which will most effectively utilize the available parts. Assembly must be scheduled to efficiently utilize available assembly benches while still maintaining flight schedules. Assembled components must be assigned to as many contiguous flights as possible, to minimize component changes. Each component must undergo a rigorous testing program prior to flight. In addition, testing and assembly of flight engines and components must be done in conjunction with the assembly and testing of developmental engines and components. The development, testing, manufacture, and flight assignments of the engine fleet involves the satisfaction of many logistical and operational requirements, subject to many constraints. The purpose of the SSME Component Assembly and Life Management Expert System (CALMES) is to assist the engine assembly and scheduling process, and to insure that these activities utilize available resources as efficiently as possible.

Ali, M.↗
NASA NTRS2007

Development of a Cryogenic Thermal Distortion Measurement Facility for Testing the James Webb Space Telescope Instrument Support Integration Module 2-D Test Assemblies

The James Webb Space Telescope Instrument Support Integration Module (ISIM) is being designed and developed at the Goddard Space Flight Center. The ISM Thermal Distortion Testing (ITDT) program was started with the primary objective to validate the ISM mechanical design process. The ITDT effort seeks to establish confidence and demonstrate the ability to predict thermal distortion in composite structures at cryogenic temperatures using solid element models. This-program's goal is to better ensure that ISIM meets all the mechanical and structural requirements by using test results to verify or improve structural modeling techniques. The first step to accomplish the ITDT objectives was to design, and then construct solid element models of a series 2-D test assemblies that represent critical building blocks of the ISIM structure. Second, the actual test assemblies consisting of composite tubes and invar end fittings were fabricated and tested for thermal distortion. This paper presents the development of the GSFC Cryo Distortion Measurement Facility (CDMF) to meet the requirements of the ISIM 2-D test. assemblies, and other future ISIM testing needs. The CDMF provides efficient cooling with both a single, and two-stage cryo-cooler. Temperature uniformity of the test assemblies during thermal transients and at steady state is accomplished by using sapphire windows for all of the optical ports on the radiation shields and by using .thermal straps to cool the test assemblies. Numerical thermal models of the test assemblies were used to predict the temperature uniformity of the parts during cooldown and at steady state. Results of these models are compared to actual temperature data from the tests. Temperature sensors with a 0.25K precision were used to insure that test assembly gradients did not exceed 2K lateral, and 4K axially. The thermal distortions of two assemblies were measured during six thermal cycles from 320K to 35K using laser interferometers. The standard deviation for all of the distortion measurements is less than 0.5 microns, which falls within the ISIM requirement of 3 microns.

Miller, Franklin↗
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 NTRSDate not supplied

Supervised Autonomous Assembly to Create and Evolve Persistent Assets

Supervised autonomous assembly (SAA) will create a paradigm shift in the planning and design of future persistent assets (PAs), both in near zero-g environments and on planetary surfaces. SAA refers to an autonomy approach that has the benefits of autonomous assembly as well as the benefits provided by a supervisor (operator) who is available to resolve unexpected situations. SAA provides both increased design freedom as well as reduced programmatic risk. SAA enables evolution of future PAs over decades as in-space operations transition from single purpose missions to creation of PAs, such as laboratories and experimental stations which more closely resembling terrestrial laboratories that can easily adapt and evolve to new missions leveraging repeated visits to the PA. The ability to evolve enables PAs to rapidly respond to changing objectives resulting from new questions as our understanding improves. A recently initiated National Aeronautics and Space Administration (NASA) project in the Space Technology Mission Directorate (STMD) Game Changing Development (GCD) Program called the Precision Assembled Space Structure (PASS), leverages the advantages of SAA to develop technologies that enable efficient creation and evolution of hexagonal topologies; both planar (example: fuel depots) and curved (examples: telescopes and shelters). PASS will be used to provide context for the philosophy and concepts discussed as well as the decision and selections made. PASS objectives are: a) Develop confidence in SAA and on-orbit servicing, assembly and manufacturing (OSAM) technologies by executing a test campaign that uses a path-to-flight autonomous precision assembly process directly applicable to future space telescopes. b) Test autonomous technologies including automated path planning and error recovery, to emphasize a robust approach that relies on generic robots and special purpose tools. c) Validate critical component models using a digital twin that includes the assembled primary mirror support structure and assembly process. A digital twin is a high-fidelity simulation of the asset capable of predicting the on-orbit performance. The paper concludes after identifying the critical need for a modest assembly flight experiment to validate and develop confidence in the SAA paradigm, thus accelerating adoption of the benefits described. SAA is a game changing paradigm that enhances the ability of an organization to infuse new technology through rapid evolution of PAs while leveraging OSAM technologies.

Structural Modeling↗
NASA NTRS1982

Mobile work station concept for assembly of large space structures (zero gravity simulation tests)

The concept presented is intended to enhance astronaut assembly of truss structure that is either too large or complex to fold for efficient Shuttle delivery to orbit. The potential of augmented astronaut assembly is illustrated by applying the result of the tests to a barebones assembly of a truss structure. If this structure were assembled from the same nestable struts that were used in the Mobile Work Station assembly tests, the spacecraft would be 55 meters in diameter and consist of about 500 struts. The struts could be packaged in less than 1/2% of the Shuttle cargo bay volume and would take up approximately 3% of the mass lift capability. They could be assembled in approximately four hours. This assembly concept for erectable structures is not only feasible, but could be used to significant economic advantage by permitting the superior packaging feature of erectable structures to be exploited and thereby reduce expensive Shuttle delivery flights.

Heard, W. L., Jr.↗
NASA NTRS1987

Telerobotic truss assembly

The ACCESS truss was telerobotically assembled in order to gain experience with robotic assembly of hardware designed for astronaut extravehicular (EVA) assembly. Tight alignment constraints of the ACCESS hardware made telerobotic assembly difficult. A wider alignment envelope and a compliant end effector would have reduced the problem. The manipulator had no linear motion capability, but many of the assembly operations required straight line motion. The manipulator was attached to a motion table in order to provide the X, Y, and Z translations needed. A programmable robot with linear translation capability would have eliminated the need for the motion table and streamlined the assembly. Poor depth perception was a major problem. Shaded paint schemes and alignment lines were helpful in reducing this problem. The four cameras used worked well for only some operations. It was not possible to identify camera locations that worked well for all assembly steps. More cameras or movable cameras would have simplified some operations. The audio feedback system was useful.

Sheridan, Philip L.↗
NASA NTRS2003

Method for providing concentricity of pilot fuel assembly in a combustor

Concentric installation of a pilot fuel assembly in an opening in a gas turbine combustor casing is achieved by providing a boss having at least two flat surfaces which are perpendicular to each other on the combustor casing surrounding the opening and a mounting flange having at least two flat surfaces which are perpendicular to each other on the pilot fuel assembly. The pilot fuel assembly is concentrically installed to the combustor casing by inserting the assembly into the combustor casing opening, and moving the pilot fuel assembly as far as it will go in a first direction substantially parallel to one of the flat boss surfaces. The distance between the other flat boss surface and one of the flat flange surfaces is then taken. Next, the pilot fuel assembly is moved in the direction opposite the first direction, at which point, the distance between the same two flat surfaces is again measured. Lastly, the pilot fuel assembly is located at a position where the distance between the two measuring surfaces is equal to the average of the first and second measurements. If desired, these steps can be repeated back and forth along an axis perpendicular to the first and second directions.

Halila, Ely E.↗
NASA NTRS2009

Assemblies of Conformal Tanks

Assemblies of tanks having shapes that conform to each other and/or conform to other proximate objects have been investigated for use in storing fuels and oxidizers in small available spaces in upper stages of spacecraft. Such assemblies might also prove useful in aircraft, automobiles, boats, and other terrestrial vehicles in which space available for tanks is limited. The basic concept of using conformal tanks to maximize the utilization of limited space is not new in itself: for example, conformal tanks are used in some automobiles to store windshield -washer liquid and coolant that overflows from radiators. The novelty of the present development lies in the concept of an assembly of smaller conformal tanks, as distinguished from a single larger conformal tank. In an assembly of smaller tanks, it would be possible to store different liquids in different tanks. Even if the same liquid were stored in all the tanks, the assembly would offer an advantage by reducing the mechanical disturbance caused by sloshing of fuel in a single larger tank: indeed, the requirement to reduce sloshing is critical in some applications. The figure shows a prototype assembly of conformal tanks. Each tank was fabricated by (1) copper plating a wax tank mandrel to form a liner and (2) wrapping and curing layers of graphite/epoxy composite to form a shell supporting the liner. In this case, the conformal tank surfaces are flat ones where they come in contact with the adjacent tanks. A band of fibers around the outside binds the tanks together tightly in the assembly, which has a quasi-toroidal shape. For proper functioning, it would be necessary to maintain equal pressure in all the tanks.

DeLay, Tom↗
NASA NTRS2013

Precise Truss Assembly using Commodity Parts and Low Precision Welding

We describe an Intelligent Precision Jigging Robot (IPJR), which allows high precision assembly of commodity parts with low-precision bonding. We present preliminary experiments in 2D that are motivated by the problem of assembling a space telescope optical bench on orbit using inexpensive, stock hardware and low-precision welding. An IPJR is a robot that acts as the precise "jigging", holding parts of a local 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 (in this case, 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. We report the challenges of designing the IPJR hardware and software, analyze the error in assembly, document the test results over several experiments including a large-scale ring structure, and describe future work to implement the IPJR in 3D and with micron precision.

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 NTRS2016

Cryogenic Fiber Optic Assemblies for Spaceflight Environments: Design, Manufacturing, Testing, and Integration

Fiber optic assemblies have been used on spaceflight missions for many years as an enabling technology for routing, transmitting, and detecting optical signals. Due to the overwhelming success of NASA in implementing fiber optic assemblies on spaceflight science-based instruments, system scientists increasingly request fibers that perform in extreme environments while still maintaining very high optical transmission, stability, and reliability. Many new applications require fiber optic assemblies that will operate down to cryogenic temperatures as low as 20 Kelvin. In order for the fiber assemblies to operate with little loss in optical throughput at these extreme temperatures requires a system level approach all the way from how the fiber assembly is manufactured to how it is held, routed, and integrated. The NASA Goddard Code 562 Photonics Group has been designing, manufacturing, testing, and integrating fiber optics for spaceflight and other high reliability applications for nearly 20 years. Design techniques and lessons learned over the years are consistently applied to developing new fiber optic assemblies that meet these demanding environments. System level trades, fiber assembly design methods, manufacturing, testing, and integration will be discussed. Specific recent examples of ground support equipment for the James Webb Space Telescope (JWST); the Ice, Cloud and Land Elevation Satellite-2 (ICESat-2); and others will be included.

Fiber Optic↗
NASA NTRS2018

Discrete Assemblers Utilizing Conventional Motion Systems

An alternative to additive manufacturing is disclosed, introducing an end-to-end workflow in which discrete building blocks are reversibly joined to produce assemblies called digital materials. Described is the design of the bulk-material building blocks and the devices that are assembled from them. Detailed is the design and implementation of an automated assembler, which takes advantage of the digital material structure to avoid positioning errors within a large tolerance. To generate assembly sequences, a novel CAD/CAM workflow is described for designing, simulating, and assembling digital materials. The structures assembled using this process have been evaluated, showing that the joints perform well under varying conditions and that the assembled structures are functionally precise.

Langford, William Kai↗
NASA NTRS2019

A Simple Transient Thermal Test Assembly for Insulation Materials

A simple transient thermal test was developed for evaluating the thermal performance of high-temperature flexible insulation materials in atmospheric pressure air. The test setup was inspired by the test assembly used for evaluating the performance of fire shelters and fire protective clothing. The heating source used was a burner supplied with propane gas that can generate relatively uniform heating over a wide area. The ratio of the in-plane width to thickness of the insulation test sample in the test assembly was selected to be greater than ten so that the heat transfer in the center of the test assembly was nearly one-dimensional. A rigid, thin Inconel plate was used as the septum plate directly exposed to the flame to provide a relatively uniform, known-temperature boundary condition for the test assembly, and to prevent convective heat transfer through the test insulation from the burner. The test sample, flexible alumina paper insulation, was placed between the Inconel plate and a thin titanium witness plate. The overall assembly was further insulated using a combination of rigid and flexible ceramic insulations to minimize heat losses from the periphery of the test assembly. Thermocouples installed on the septum and witness plates and inside the insulation test sample provided temperature measurements at various locations. For the evaluation tests, the Inconel septum plate reached temperatures between 780°C and 850°C for tests with flame exposure durations of 120 sec to 300 sec. The measured temperatures for various tests with similar flame exposure times were repeatable. A one-dimensional numerical heat transfer model of the test assembly was developed. The close agreement between measured and predicted temperatures on the titanium witness plate and inside the insulation test sample indicated that this test may provide a one-dimensional thermal testing capability for evaluation of thermal performance of similar insulations.

Daryabeigi, Kamran↗