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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.

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All sourcesNASA NTRSDOE OSTI
NASA NTRS2019

STF-1 Ground Operations - Automating the Planning, Scheduling, Assessment and Data Processing/Reduction for a Small Satellite

On December 16, 2018, a 3-U CubeSat named STF-1 launched as West Virginia's first spacecraft. This event marked the culmination of a run-up to launch involving the production of the spacecraft, creation/configuration of command and control infrastructure, and the evolution of its co-creation, the NASA Operational Simulator for Small Satellites (NOS3). This event also marked the beginning of a new phase: operations. While plans, procedures, and infrastructure were already in place or started for operations, many lessons were learned during the operations phase, especially during early operations (first month/commissioning phase). Additional plans, procedures, and infrastructure, especially related to communication planning and automated data processing, were created and developed to fill needs for the operation of the STF-1 mission.This paper and presentation will overview the STF-1 operations team's solutions to addressing the many needs of operating a low-earth orbiting CubeSat mission with a single ground antenna that is shared and scheduled with several other missions. The STF-1 operations team deployed a combination of virtualization technologies, ground station technology solutions, collaboration software, custom planning software solutions, and existing ground antenna scheduling solutions to create an effective and efficient CubeSat operations environment. The end-solution satisfied the operations stakeholders, which include NASA, its industry partner TMC2 Technologies, and four independent professor-student teams at West Virginia University.

Suder, Mark↗
DOE OSTI2024

Navigating Options for Transportation Electrification and Solar Charging: Steps and Lessons Learned in Montana Communities

This document is intended to assist communities who are considering investing in electric transportation. It can assist communities engage stakeholders, prioritize community goals, assess electric transportation options, and navigate complex decisions about deploying zero emission electric transportation in their community. It covers technological, economic and environmental aspects of the transition to electric vehicles (EV), and highlights the specific considerations related to the deployment of renewable energy technologies (e.g., distributed solar) in combination with EV supply equipment (EVSE, e.g., charging stations). There are many important decisions to make and questions for communities to ask themselves as they consider electric vehicle types, charging infrastructure, and electricity generation options. This guide will help communities assess: (1) Which stage in the decision-making process they are in with respect to EV deployment; (2) Questions they can explore to guide their decisions about EV deployment; (3) How to engage key stakeholders on EV deployment options; (4) Tradeoffs and benefits of various electric transportation options and; (5) Synergies of pairing electric vehicle charging and renewable energy generation technologies. The analysis and lessons learned presented in this roadmap are intended to serve as a template and guide for similarly situated communities across the country who want to prepare for and play a role in the electrified transportation future.

14 SOLAR ENERGY↗
NASA NTRS1994

Teacher Enhancement Institute

In a team building, team teaching strategy with four faculty, can learning strategies such as educational technology and problem based learning be provided to forty local teachers of primary, elementary, and secondary students? The impetus for the effort is to provide information about science and engineering at NASA and motivate students to pursue careers in science and technology. Teachers, identified and selected through a rigorous application procedure, participated in a two week workshop for a graduate credit. Teachers were exposed to computer applications such as INTERNET, MOSAIC, Power Machintosh word processing, NASA scientists, and laboratory experiments. Teachers were evaluated on level and quality of their participation, design of teacher application materials and relevant lesson plans and presentations. The results show that teachers, regardless of preparation and background, can learn science and engineering applications and develop relevant materials to transfer information to their classroom. Follow-up during the academic year will show that teachers are successfully using materials.

Simmons, Ron W.↗
NASA NTRS1994

The Network Operations Control Center upgrade task: Lessons learned

This article synthesizes and describes the lessons learned from the Network Operations Control Center (NOCC) upgrade project, from the requirements phase through development and test and transfer. At the outset, the NOCC upgrade was being performed simultaneously with two other interfacing and dependent upgrades at the Signal Processing Center (SPC) and Ground Communications Facility (GCF), thereby adding a significant measure of complexity to the management and overall coordination of the development and transfer-to-operations (DTO) effort. Like other success stories, this project carried with it the traditional elements of top management support and exceptional dedication of cognizant personnel. Additionally, there were several NOCC-specific reasons for success, such as end-to-end system engineering, adoption of open-system architecture, thorough requirements management, and use of appropriate off-the-shelf technologies. On the other hand, there were several difficulties, such as ill-defined external interfaces, transition issues caused by new communications protocols, ambivalent use of two sets of policies and standards, and mistailoring of the new JPL management standard (due to the lack of practical guidelines). This article highlights the key lessons learned, as a means of constructive suggestions for the benefit of future projects.

Sherif, J. S.↗
NASA NTRS2004

Assessment of High-Voltage Photovoltaic Technologies for the Design of a Direct Drive Hall Effect Thruster Solar Array

A three-year program to develop a Direct Drive Hall-Effect Thruster system (D2HET) begun in 2001 as part of the NASA Advanced Cross-Enterprise Technology Development initiative. The system, which is expected to reduce significantly the power processing, complexity, weight, and cost over conventional low-voltage systems, will employ solar arrays that operate at voltages higher than (or equal to) 300 V. The lessons learned from the development of the technology also promise to become a stepping-stone for the production of the next generation of power systems employing high voltage solar arrays. This paper summarizes the results from experiments conducted mainly at the NASA Marshal Space Flight Center with two main solar array technologies. The experiments focused on electron collection and arcing studies, when the solar cells operated at high voltages. The tests utilized small coupons representative of each solar array technology. A hollow cathode was used to emulate parts of the induced environment on the solar arrays, mostly the low-energy charge-exchange plasma (1012-1013 m-3 and 0.5-1 eV). Results and conclusions from modeling of electron collection are also summarized. The observations from the total effort are used to propose a preliminary, new solar array design for 2 kW and 30-40 kW class, deep space missions that may employ a single or a cluster of Hall- Effect thrusters.

Mikellides, I. G.↗
NASA NTRS2006

Solid Modeling of Crew Exploration Vehicle Structure Concepts for Mass Optimization

Parametric solid and surface models of the crew exploration vehicle (CEV) command module (CM) structure concepts are developed for rapid finite element analyses, structural sizing and estimation of optimal structural mass. The effects of the structural configuration and critical design parameters on the stress distribution are visualized, examined to arrive at an efficient design. The CM structural components consisted of the outer heat shield, inner pressurized crew cabin, ring bulkhead and spars. For this study only the internal cabin pressure load case is considered. Component stress, deflection, margins of safety and mass are used as design goodness criteria. The design scenario is explored by changing the component thickness parameters and materials until an acceptable design is achieved. Aluminum alloy, titanium alloy and an advanced composite material properties are considered for the stress analysis and the results are compared as a part of lessons learned and to build up a structural component sizing knowledge base for the future CEV technology support. This independent structural analysis and the design scenario based optimization process may also facilitate better CM structural definition and rapid prototyping.

Mukhopadhyay, Vivek↗
NASA NTRS2009

NASA Composite Materials Development: Lessons Learned and Future Challenges

Composite materials have emerged as the materials of choice for increasing the performance and reducing the weight and cost of military, general aviation, and transport aircraft and space launch vehicles. Major advancements have been made in the ability to design, fabricate, and analyze large complex aerospace structures. The recent efforts by Boeing and Airbus to incorporate composite into primary load carrying structures of large commercial transports and to certify the airworthiness of these structures is evidence of the significant advancements made in understanding and use of these materials in real world aircraft. NASA has been engaged in research on composites since the late 1960 s and has worked to address many development issues with these materials in an effort to ensure safety, improve performance, and improve affordability of air travel for the public good. This research has ranged from synthesis of advanced resin chemistries to development of mathematical analyses tools to reliably predict the response of built-up structures under combined load conditions. The lessons learned from this research are highlighted with specific examples to illustrate the problems encountered and solutions to these problems. Examples include specific technologies related to environmental effects, processing science, fabrication technologies, nondestructive inspection, damage tolerance, micromechanics, structural mechanics, and residual life prediction. The current state of the technology is reviewed and key issues requiring additional research identified. Also, grand challenges to be solved for expanded use of composites in aero structures are identified.

Tenney, Darrel R.↗
NASA NTRS2011

The Effect of Different Operations Modes on Science Capabilities During the 2010 Desert-RATS Test: Insights from the Geologist Crewmembers

The 2010 Desert RATS field test utilized two Space Exploration Vehicles (prototype planetary rovers) and four crewmembers (2 per rover) to conduct a geologic traverse across northern Arizona while testing continuous and twice-per-day communications paired with operation modes of separating and exploring individually (Divide & Conquer) and exploring together (Lead & Follow), respectively. This report provides qualitative conclusions from the geologist crewmembers involved in this test as to how these modes of communications and operations affected our ability to conduct field geology. Each mode of communication and operation provided beneficial capabilities that might be further explored for future Human Spaceflight Missions to other solar system objects. We find that more frequent interactions between crews and an Apollo-style Science Team on the Earth best enables scientific progress during human exploration. However, during multiple vehicle missions, this communication with an Earth-based team of scientists, who represent "more minds on the problem", should not come at the exclusion of (or significantly decrease) communication between the crewmembers in different vehicles who have the "eyes on the ground". Inter-crew communications improved when discussions with a backroom were infrequent. Both aspects are critical and cannot be mutually exclusive. Increased vehicle separation distances best enable encounters with multiple geologic units. However, seemingly redundant visits by multiple vehicles to the same feature can be utilized to provide improved process-related observations about the development and modification of the local terrain. We consider the value of data management, transfer, and accessibility to be the most important lesson learned. Crews and backrooms should have access to all data and related interpretations within the mission in as close to real-time conditions as possible. This ensures that while on another planetary surface, crewmembers are as educated as possible with respect to the observations and data they will need to collect at any moment.

Bleacher, Jacob E.↗
NASA NTRS2021

Assembly of the IXPE Mirror Modules

Expected to launch in December 2021, the Imaging X-ray Polarimetry Explorer (IXPE) is a NASA Astrophysics Small Explorer Mission with significant contributions from the Italian space agency (ASI). Three identical x-ray telescopes combine to form the IXPE Observatory. Each is comprised of a 4-m-focal length mirror module assembly (MMA, provided by Marshall Space Flight Center) that focuses x-rays onto a polarization-sensitive, imaging detector (contributed by ASI-funded institutions). This paper describes the now-completed assembly process for the 3 flight and one spare mirror modules, and compares as-tested calibrated performance with as-built metrology data. Unexpected challenges and lessons-learned are also discussed.

X-ray optics IXPE polarimetry↗
DOE OSTI2020

Lessons Learned from Hanford's Purex Tunnel 2 Structural Stabilization Project - 20509

In 2019, U.S. Department of Energy (DOE) contractor CH2M Hill Plateau Remediation Company (CHPRC) completed structurally stabilizing the Plutonium Uranium Extraction Plant (Purex) waste storage Tunnel 2 with engineered grout. This action significantly reduced risk to Hanford workers, the surrounding community and environment by preventing future collapse of the tunnel and possible release of radioactive materials. Decades of plutonium production at the Purex facility required construction of two large underground tunnels for storage of highly contaminated plutonium processing equipment that had failed during the operation of Purex and other facilities across the Hanford Site. Following the partial collapse of Purex Tunnel 1 on May 9, 2017, DOE and CHPRC took immediate action to safely stabilize the collapsed section of the tunnel. The hole in the tunnel was filled the next day as a temporary stabilization measure, and no contamination was detected as a result of the partial collapse of the tunnel. Workers then stabilized Tunnel 1 in its entirety by filling with engineered grout, which also encapsulated the radioactive equipment and railcars within the tunnel. Grouting eliminated the risk of further collapse and stabilized the tunnel contents, all while not precluding future remedial actions or final closure decisions. While conducting an integrity analysis of Tunnel 1 by using construction drawings, photos and other historical documents, project teams also analyzed the much larger Purex Tunnel 2. The analysis found Tunnel 2 did not meet current codes for structural integrity, and it may not be able to bear the weight of the soil above the tunnel. Therefore, it was determined that Tunnel 2 was also at risk of collapse. DoE's independent panel of experts determined grouting to be the best choice for stabilizing Tunnel 2 because it provides the highest level of stability and protection, and does not preclude future remedial actions. DOE authorized CHPRC to commence work and the Purex Tunnel 2 Structural Stabilization Project was launched in December of 2017. The paper will discuss the process of recognizing the following critical aspects and risks associated with stabilizing Tunnel 2, and the actions taken by the project team to mitigate these risks, including: - Tunnel investigation and data collection to assist with future remediation; - On-site batching and mock-ups to provide the large quantity of grout required for stabilizing the tunnel; - Workforce involvement and innovative actions that mitigated the project's most significant potential hazards, including traffic control; - Project team high level of execution translated into successful project execution. Sharing lessons learned from this critical risk-reduction effort can enhance the safety and efficiency of other complex and hazardous projects across the DOE complex. (authors)

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗
DOE OSTI2025

A Multi-Sensor Approach for Measuring Bird and Bat Collisions with Offshore Wind Turbines (Final Technical Report)

Collision of birds and bats with wind turbines is a conservation concern for both land-based and offshore wind projects. The fatality rates of birds and bats at land-based turbines are well documented. The measurement strategies on land focus on finding carcasses following collision, estimating the number of carcasses missed through searcher efficiency, carcass persistence trials and carcass fall distributions, and modeling statistically robust fatality rates. Few technologies have been developed to monitor offshore bird and bat collisions, and many that have been developed focused on detecting collisions with large birds. The few studies that have attempted to document collisions at offshore turbines do not account for smaller bodied animals or for collisions that might be missed, which prevents the calculation of statistically robust fatality rates. The overall goal of this report, A Multi-Sensor Approach for Measuring Bird and Bat Collisions with Offshore Wind Turbines (Project), was to develop an effective multi-sensor system for quantifying bird and bat collision rates, specifically for offshore wind facilities. The Project goal and resulting automated collision detection system was achieved through two major technological advancements: 1) refining The Netherlands Organisation for Applied Scientific Research’s (TNO’s) existing WT-Bird® vibration sensing system, that had successfully detected large bird collisions during daytime, to allow for improved detection of smaller birds and bats during both daytime and nighttime hours and 2) improving image processing systems and developing and integrating machine learning algorithms to automatically detect and classify small and large bird and bat collisions with offshore turbines. This final technical report (FTR) summarizes Methods , Results , Conclusions , and Lessons Learned during each of the five Tasks identified for this research and development effort. This FTR includes summaries of the following: Task 1. Initial Engineering Tests to Improve WT-Bird® Task 2. Installation of WT‐Bird® on a Utility-scale Turbine at the National Wind Technology Center – National Renewable Energy Laboratory Task 3. Field Tests and Refinement of the Object Detection System Task 4. Validation of WT-Bird® on a Land-based Turbine Task 5. Preparation for the Implementation of WT-Bird® on an Offshore Turbine. This research and development effort documented successful improvement of the WT Bird® collision detection system to detect small birds and bats, and WT-Bird® is the first collision detection system to validate results compared to land-based post-construction monitoring. The collision trials provide estimates of missed targets that can be used to estimate fatality rates, a significant improvement relative to other offshore collision monitoring systems. Advances were made in developing an edge-processing solution to reduce data storage requirements, which is important if the system is deployed for long periods of time at offshore turbines. The improved WT-Bird® system also provides an important option for wind operators on land or offshore who need to document specific details about when collisions occur, particularly efforts to further research on bat impact minimization, or when standard fatality searches are impractical (e.g. offshore) or inadequate (e.g. challenging locations on land).

17 WIND ENERGY↗
NASA NTRS2007

Lessons Learned from the Aquarius Radiometer Engineering Model

The Aquarius instrument is a combination microwave radiometer and scatterometer operating in the L-band for the measurement of sea surface salinity (SSS) over the open-ocean. "The Aquarius science goals are to observe and model the processes that relate salinity variations to climatic changes in the global cycling of water and to understand how these variations influence the general ocean circulation. By measuring salinity globally and synoptically every month for 3 years, Aquarius will provide an unprecedented new view of the ocean's role in climate." (http://aquarius.asfc.nasa.gov on Jan. 4, 2007). To launch in 2009, Aquarius will provide 8-day global coverage and monthly-averaged salinity maps at approx.120-km spatial resolution. Because the microwave emissivity of the ocean surface is weakly dependent upon salinity, the Aquarius radiometer remain sufficiently stable to provide accurate salinity measurements. An engineering model (EM) of one radiometer receiver was developed and tested for functionality and performance at NASA's Goddard Space Flight Center. It was tested for long-term stability starting July 27,2006. Two discrepancies where found at the start of testing and a four-month correction process ensued. This paper covers the testing and debugging of the EM radiometer through resolution of the problems. The radiometer is required to have calibration stability of less than or equal to 0.15 K over 7 days. The radiometer is in a three-beam push-broom configuration with each beam being an independent three-state Dicke radiometer (antenna, reference load, and additive noise). Internal noise diodes and reference loads provide periodic and rapid calibration of the receiver. Front-end loss contributions must be corrected as the lossy components are outside the calibration loop. A key design feature for obtaining stability is active thermal control of the front-end lossy components and the RF receiver. The thermal stability is predicted to be about 0.1 C over an orbit and no more than 1 C over a year. The radiometric stability requirement is 0.13 K rms 1 7 days without using temperature corrections. Temperature corrections and post-launch calibration are expected to extend the stability period through the life of the mission.

Piepmeier, Jeffrey↗
NASA NTRS2020

Broadening JPL’s Mission Formulation Paradigm with Human Centered Design

Within NASA’s highly competitive environment for funding, Human Centered Design (HCD) and cybernetics could provide advantages to proposers during the mission formulation phase. Opportunities are limited when it comes to funding new science missions. Proposers are challenged to make a compelling case about the scientific desirability, technical feasibility, and resource viability of their concepts. Organizations follow established processes for proposal development using teams that typically include scientists, engineers, and managers. These team members are highly experienced subject matter experts (SME) in their own disciplines, and can respond to requirements from the solicitation. However, they are typically not trained as designers and communicators. Their approach is rooted within NASA’s science and technology paradigm. How can we improve the proposal development process, refine workflow between team members, and deliver clear and appealing offerings to the stakeholders and evaluators? These questions have been addressed by today’s most innovative companies (e.g., Apple, Google, 3M, Dyson), where the design process is not limited simply to engineering and management, but involves an all-encompassing approach drawing from fields such as social sciences, design, and the arts. Like these commercial enterprises, NASA currently employs systems thinking and integrated design, but can benefit further by moving beyond its current practices, which are mostly driven by rigid engineering, technology, science, and project management considerations. At JPL’s Innovation Foundry and through the Solar System Mission Formulation Office, we broadened this paradigm by including HCD in the mission formulation workflow. Our goal was to create a proposal with improved clarity and appeal, thus helping our team to communicate its message and aid evaluators with their work. In this paper we provide examples and lessons learned from our recent proposal development effort using HCD. We discuss touch points where we infused non-linear designerly approaches and cybernetic circularity into the workflow. Implemented design topics include operational design for team building; process design throughout distinct phases of the proposal development and writing process; communication design for streamlined exchange of information within the team and to stakeholders; interaction design; graphic design; and creating boundary objects. While these approaches may feel new or foreign to SMEs and managers in the aerospace community, they produced significant benefits in this mission formulation effort. We will describe how such approaches can be used to broaden NASA’s technology-driven paradigm through design, thus creating an environment which fosters innovation, improved communication, and strategic advantage for proposers and their organizations.

Turner, Neal↗
DOE OSTI2022

Comparing the effect of virtual and in-person instruction on students’ performance in a design for additive manufacturing learning activity

The goal of this work is to compare the outcome of a design for additive manufacturing (DfAM) heuristics lesson conducted in a virtual learning environment to the same in an in-person learning environment. Prior work revealed that receiving DfAM heuristics at different points in the design process impacts the quality and novelty of designs produced afterward, but this work may have been limited by the solely virtual format. In this work, an identical experiment was performed in a face-to-face learning environment. Results indicate that neither learning format presents an advantage over the other when it comes to the quality of designs produced during the intervention. Participants across all experimental groups reported an increase in self-efficacy after the intervention, with improved performance on quiz-type questions. Furthermore, the novelty and variety of the designs produced by the in-person experimental groups were significantly lower than that of the virtual experimental groups. In addition to validating the effectiveness of virtual instruction as a teaching method, these results also support the authors’ hypothesis that the priming effect is stronger in an in-person classroom than in a virtual classroom.

Design for additive manufacturing↗
NASA NTRS1998

Technical Assessment of the National Full Scale Aerodynamic Complex Fan Blades Repair

This report describes the principal activities of a technical review team formed to address National Full Scale Aerodynamic Complex (NFAC) blade repair problems. In particular, the problem of lack of good adhesive bonding of the composite overwrap to the Hyduliginum wood blade material was studied extensively. Description of action plans and technical elements of the plans are provided. Results of experiments designed to optimize the bonding process and bonding strengths obtained on a full scale blade using a two-step cure process with adhesive primers are presented. Consensus recommendations developed by the review team in conjunction with the NASA Ames Fan Blade Repair Project Team are provided along with lessons learned on this program. Implementation of recommendations resulted in achieving good adhesive bonds between the composite materials and wooden blades, thereby providing assurance that the repaired fan blades will meet or exceed operational life requirements.

Young, Clarence P., Jr.↗
NASA NTRS2010

Mars Science Laboratory Sample Acquisition, Sample Processing and Handling: Subsystem Design and Test Challenges

The Sample Acquisition/Sample Processing and Handling subsystem for the Mars Science Laboratory is a highly-mechanized, Rover-based sampling system that acquires powdered rock and regolith samples from the Martian surface, sorts the samples into fine particles through sieving, and delivers small portions of the powder into two science instruments inside the Rover. SA/SPaH utilizes 17 actuated degrees-of-freedom to perform the functions needed to produce 5 sample pathways in support of the scientific investigation on Mars. Both hardware redundancy and functional redundancy are employed in configuring this sampling system so some functionality is retained even with the loss of a degree-of-freedom. Intentional dynamic environments are created to move sample while vibration isolators attenuate this environment at the sensitive instruments located near the dynamic sources. In addition to the typical flight hardware qualification test program, two additional types of testing are essential for this kind of sampling system: characterization of the intentionally-created dynamic environment and testing of the sample acquisition and processing hardware functions using Mars analog materials in a low pressure environment. The overall subsystem design and configuration are discussed along with some of the challenges, tradeoffs, and lessons learned in the areas of fault tolerance, intentional dynamic environments, and special testing

Jandura, Louise↗
NASA NTRS2013

High-Strength, Superelastic Compounds

In a previous disclosure, the use of 60- NiTiNOL, an ordered intermetallic compound composed of 60 weight percent nickel and 40 weight percent titanium, was investigated as a material for advanced aerospace bearings due to its unique combination of physical properties. Lessons learned during the development of applications for this material have led to the discovery that, with the addition of a ternary element, the resulting material can be thermally processed at a lower temperature to attain the same desirable hardness level as the original material. Processing at a lower temperature is beneficial, not only because it reduces processing costs from energy consumption, but because it also significantly reduces the possibility of quench cracking and thermal distortion, which have been problematic with the original material. A family of ternary substitutions has been identified, including Hf and Zr in various atomic percentages with varying concentrations of Ni and Ti. In the present innovation, a ternary intermetallic compound consisting of 57.6 weight percent Ni, 39.2 weight percent Ti, and 3.2 weight percent Hf (54Ni-45Ti-1Hf atomic percent) was prepared by casting. In this material, Hf substitutes for some of the Ti atoms in the material. In an alternate embodiment of the innovation, Zr, which is close in chemical behavior to Hf, is used as the substitutional element. With either substitution, the solvus temperature of the material is reduced, and lower temperatures can be used to obtain the necessary hardness values. The advantages of this innovation include the ability to solution-treat the material at a lower temperature and still achieve the required hardness for bearings (at least 50 Rockwell C) and superelastic behavior with recoverable strains greater than 2%. Most structural alloys will not return to their original shape after being deformed as little as 0.2% (a tenth of that possible with superelastic materials like 60 NiTiNOL). Because lower temperatures can be used in the heat treatment process, less energy will be consumed, and there will be less dimensional distortion and quench cracking. This results in fewer scrap parts, less material waste from large amounts of material removal, and fewer machining steps to rework parts that are out of specification. This material has a combination of properties that have been previously unobtainable. The material has a Young s modulus of approximately 95 GPa (about half that of conventional steels), moderate density (10 to 15% lower than conventional steels), excellent corrosion resistance, and high hardness (58 to 62 HRC). These properties make this material uniquely suited for advanced bearings.

Stanford, Malcolm↗
NASA NTRSDate not supplied

Recovering from On-orbit Anomalies on the Astrobee Free Flyers and its Systems

Since 2019, NASA has been operating three Astrobee free flying robots on board the International Space Station (ISS) providing an autonomous and flexible research platform for national and international payload developers in microgravity and serving as a robotic assistant for astronauts on the ISS. During its use on the ISS, in particular with over 750 hours of free-flyer operation as of March 2022, Astrobee and its Docking Station have encountered multiple software and hardware anomalies. These anomalies were either resolved remotely via software and firmware updates, or, where not possible, with hardware replacements on orbit or by the return of the faulty unit to NASA’s ground facilities for its repair. Despite being inherently designed to be repaired or replaced on orbit, Astrobee and its systems can still suffer anomalies that would be complex enough to disassemble, cause risks of hardware damage, or use excessive crew time to perform the repair in orbit. That was the case for the anomaly the Astrobee unit ‘Honey’ encountered, reason why it needed to be down-massed for repair. One of the most common points of failure was found to be the SD card, which is used for the different Astrobee processors and for the Dock Station. Other comparable SD card anomalies were found also on the Astrobee ground units, which provided useful data in the effort of upgrading their systems. This presentation will focus on 1) The overview of the different faults and anomalies on Astrobee and its systems on orbit and on the ground 2) The processes and procedures implemented to resolve the anomalies 3) The implementation of software updates and hardware upgrades in order to reduce the risk on returning anomalies 4) The lessons learned in increasing Astrobee’s robustness and resilience to such anomalies.

International Space Station↗