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NASA NTRSDate not supplied

Firmware Architecture of the ARMADAS Bolting Robot

The Automated Reconfigurable Mission Adaptive Digital Assembly Systems (ARMADAS) project, under development at NASA Ames Research Center, has demonstrated on-ground autonomous robotic assembly of extensive digital structures, and it is now moving forward towards in-space demonstration. The ARMADAS system comprises of the operation software, the operation user interface (opsUI), and a swarm of robots. The robotic system consists of a multitude of collaborative agents specifically designed to transport, place and bolt the building blocks, called voxels (volumetric pixels). This paper focuses on the bolting robot, referred to as Mobile Metamaterial Internal Co-Integrator (MMIC-I). MMIC-I is a battery-powered crawling robot. It navigates the structure through extension, contraction and gripping. Two distinct controller boards operate the robot's two symmetric modules, referred to as module A and B. Board A is the master board: it coordinates motion planning and motion primitives execution, hosts the WiFi client, performs periodic self-assessment and system idle check and triggers faults if anomalies are detected. Board B periodically sends a heartbeat to board A, through a wired communication channel that uses the Serial protocol. Additionally, board A's WiFi client receives heartbeat packet requests or motion/bolting commands from a dedicated server board, and acknowledges reception sending back a response heartbeat packet containing information about the overall robot status, e. g. electrical current and voltage values, target and actual angles, operating mode, fault status. Whenever a motion command is sent, the motion planning section of the firmware determines the current robot configuration, using Inertial Measurement Unit readings and the motors Pulse Width Modulation values. Afterwards, it calculates the list of primitives needed to reach the target state, and controls their execution in the proper order. MMIC-I can receive and execute motion and bolting commands only when it is in operational mode. MMIC-I has three operating modes: standby, operational and safed. Standby mode is automatically entered upon startup. While in standby mode, all motors are powered off, and the only accepted commands are the ones relative to a change of mode and heartbeat packet request. Fault detection causes the robot to automatically enter safed or standby mode. Whenever the detected fault occurs within a motion and requires immediate intervention, e. g. an over-current situation, the robot enters safed mode. Safed mode powers off all motors except for the locomotion module, thus preventing the robot from collapsing. Conversely, when the detected fault doesn't require immediate intervention (low battery warning, for instance), the robot enters standby mode after completing the ongoing motion. This paper provides a detailed discussion of MMIC-I's firmware architecture. It accurately describes the implementation approach for each module: sensor data reading, motor control and actuation, WiFi server-client communication, intra-boards Serial communication, operating modes and autonomous fault detection, motion planning, coordination and execution, etc. Moreover, in support of the software description, this paper includes a thorough characterization of MMIC-I's hardware and avionics.

In-space assembly↗

DOE OSTI2024

Herbicide‐resistant weed management with robots: A weed ecological–economic model

The heavy reliance on herbicides for weed control has led to an increase in resistant weeds in the United States. Robotic weed control is emerging as an alternative technology for removing weeds mechanically using artificial intelligence. We develop an integrated weed ecological and economic dynamic (I‐WEED) model to examine the biophysical and economic drivers of adopting robotic weed management and simulate the optimal timing and intensity of robotic adoption within and across growing seasons. We specify a cohort‐based weed growth model that relates yield damages to effective weed density and treats the susceptibility of weeds to herbicides as a renewable resource that can be regenerated by using mechanical weeding robots, due to a fitness cost that makes resistant weeds less prolific. Compared to myopic weed management which ignores resistance development, forward‐looking management leads to earlier adoption of robots and treating robots as complements instead of substitutes to herbicides. This weed management results in adopting fewer robots, deploying robots on a smaller portion of the land, higher profitability, and lower yield loss in the long run, relative to myopic management. Counterintuitively, myopic management leads to a lower resistance level through its higher robot adoption intensity. We also find that a lower level of initial weed seed resistance and/or a higher fitness cost result in a higher level of resistance because they create incentives for farmers to delay the adoption of robotic weed control. Our analysis shows the importance of jointly considering the interactions between weed ecology and economics in analyzing the incentives and effects of robotic weed management on weed resistance.

agricultural robotics↗

DOE OSTI2016

Design and validation of an MR-conditional robot for transcranial focused ultrasound surgery in infants

Purpose: Current treatment of intraventricular hemorrhage (IVH) involves cerebral shunt placement or an invasive brain surgery. Magnetic resonance-guided focused ultrasound (MRgFUS) applied to the brains of pediatric patients presents an opportunity to treat IVH in a noninvasive manner, termed “incision-less surgery.” Current clinical and research focused ultrasound systems lack the capability to perform neonatal transcranial surgeries due to either range of motion or dexterity requirements. A novel robotic system is proposed to position a focused ultrasound transducer accurately above the head of a neonatal patient inside an MRI machine to deliver the therapy. Methods: A clinical Philips Sonalleve MRgFUS system was expanded to perform transcranial treatment. A five degree-of-freedom MR-conditional robot was designed and manufactured using MR compatible materials. The robot electronics and control were integrated into existing Philips electronics and software interfaces. The user commands the position of the robot with a graphical user interface, and is presented with real-time MR imaging of the patient throughout the surgery. The robot is validated through a series of experiments that characterize accuracy, signal-to-noise ratio degeneration of an MR image as a result of the robot, MR imaging artifacts generated by the robot, and the robot’s ability to operate in a representative surgical environment inside an MR machine. Results: Experimental results show the robot responds reliably within an MR environment, has achieved 0.59 ± 0.25 mm accuracy, does not produce severe MR-imaging artifacts, has a workspace providing sufficient coverage of a neonatal brain, and can manipulate a 5 kg payload. A full system demonstration shows these characteristics apply in an application environment. Conclusions: This paper presents a comprehensive look at the process of designing and validating a new robot from concept to implementation for use in an MR environment. An MR conditional robot has been designed and manufactured to design specifications. The system has demonstrated its feasibility as a platform for MRgFUS interventions for neonatal patients. The success of the system in experimental trials suggests that it is ready to be used for validation of the transcranial intervention in animal studies.

60 APPLIED LIFE SCIENCES↗

DOE OSTI2018

Autonomous 3D and Radiation Mapping in Tunnel Environments Using Aerial Robots - 18156

In this paper we present the algorithms and systems developed to enable autonomous 3D and radiation mapping, as well as radiological source localization in tunnel environments using aerial robots. The developed technologies aim to address the need of autonomous robotic inspection of nuclear sites such as facilities in the process of being decommissioned. As a motivational example, the PUREX tunnels at the Hanford Site are considered and the robot is designed to be able to conduct multi-modal 3D/radiation characterization of the tunnel environment without any prior knowledge or map provided beforehand. In order to enable the necessary GPS-denied simultaneous localization and mapping in dark, visually-degraded tunnel environments, a multi-modal mapping unit was developed which fuses the data from stereo vision cameras synchronized with flashing LEDs, inertial sensors, and three time-of-flight 3D depth sensors. The robot's pose and surrounding map are estimated at 20 Hz through a depth-enhanced visual- inertial localization and mapping framework. Provided this ability to estimate the robot's pose and develop a dense map in real-time, a receding horizon sampling-based autonomous exploration path planning algorithm was utilized and equips the robot with the ability to explore its environment given no prior map. The aforementioned key robotic functionalities are further extended through the integration of miniaturized fully solid-state scintillation detectors, utilizing advanced scintillators and Silicon Photomultipliers. The derived sensor data is employed for radiation mapping, which when fused with the 3D maps and the spectroscopic source localization methods, allow the aerial robotic platform to localize the radiation source and identify the specific source isotope. The source location is estimated through a geometric algorithm which can localize a source given only three measurements and short dwell times. The developed systems were tested using two small aerial robot platforms of the F450 and F550 frame classes with weights of 2.6 kg and 2.9 kg respectively. All localization and planning as well as high-level control algorithms are executed onboard. The scintillation detector is integrated on the robot and its data is collected through a dedicated microcontroller. A set of field experiments were conducted inside the dark and GPS-denied environment of a 4.25 m wide, 7.5 m tall, and 137 m long railroad tunnel. A Cs-137 source was placed within the tunnel, the associated 3D/radiation maps were derived, and the source location was estimated. Through these efforts, the goal is to develop the robotic technology that would enable the autonomous systematic inspection or emergency response in nuclear waste decommissioning facilities. (authors)

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DOE OSTI2018

Result of Investigation for Inside PCV in 1F-1 by Shape Changing Robot named PMORPH - 18617

In Fukushima Daiichi Nuclear Power Station, before retrieval of molten fuel debris inside PCV, the operation such as decontamination, survey, repair and taking sample of fuel debris are implemented step by step. In case of investigation inside primary containment vessel (PCV), some remotely operated robots have been used for because human can't access to high radiation environment. Because a radiation dose is very high in PCV, therefore it is necessary to prevent the leak of radiation from PCV when a robot is inserted in PCV. Then a pipe of 100 mm inside diameter was let go through by the PCV wall, and the seal box which was completely sealed up attached to the end of pipe. The robot is put in the seal box beforehand and is inserted inside PCV through the pipe. So it is necessary for the robot to be small. In addition, it is necessary to be stable movement on rough plane inside PCV. Therefore shape change type robot 'PMORPH' was developed. This robot consists of three parts of the slim main body and two crawlers attached to the both ends of main body. When this robot is passed in the pipe, three parts lie in a straight line like 'I' shape. And when the robot moves on a rough plane, three parts are formed like 'U' shape. We minimized the use of electric parts in the main body against high radiation environment. And this robot carries a winch to let a sensor unit descend to basement floor. And we carried out the basement floor investigation (B2 investigation) using the robot to obtain information of fuel debris condition in March, 2017. As a result, some information of basement floor condition was acquired. In this paper, it is described the outline of the shape change robot and summary of the B2 investigation. (authors)

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DOE OSTI2026

Online task-space motion control for positioner-coordinated multi-robot manufacturing systems

Incorporating multiple robotic manipulators into large-scale manufacturing systems enhances production efficiency and expands manufacturing capabilities beyond those of single-robot systems. Workpiece positioners in robotic manufacturing have demonstrated significant benefits for process optimization, but coordination strategies for multi-robot systems with shared positioners have received limited attention. This work presents a task-space coordinated trajectory-tracking control framework for multi-robot manufacturing systems, in which robots coordinate their motions within a shared, dynamic workpiece positioning frame. A workpiece positioner actively adjusts the pose of the manufactured component to enable greater operational concurrency and improve overall production efficiency. The proposed motion-coordination scheme employs a distributed and scalable architecture, supporting coordination across heterogeneous multi-robot systems. Two optimization methodologies are introduced to manage kinematic redundancies and maintain continuous, near-optimal operation throughout the manufacturing process. The first strategy exploits a task-space dimensionality reduction to achieve locally optimal configurations by leveraging symmetry-axis rotations of the tool. The second strategy utilizes the workpiece positioner to drive the coordinated robots toward stable and kinematically favorable configurations. For both optimization strategies, multiple objectives are defined to improve key performance metrics, including manipulability, configuration consistency, proximity to mechanical limits, and motion efficiency. Addressing a key limitation of existing coordination approaches, the framework is designed around online setpoint modification, allowing coordinated robots to respond effectively to in-situ process feedback. The proposed control framework is validated using the Robot Operating System (ROS) middleware on a combination of physical and simulated multi-robot system hardware.

Arbogast, Alex [ORNL] (ORCID:0000000154740723)↗

NASA NTRS1986

Theoretical three-and four-axis gimbal robot wrists

In high-performance flight simulations, a four-axis gimbal system allows all possible rotations with acceptable gimbal angle rates while it avoids the so-callled 'gimbal lock' that occurs when gimbal rotational axes are colinear. In this paper, pertinent equations (including quaternions) are assembled for a hypothetical robot wrist, functionally equivalent to this four-axis gimbal system, and also for a true three-axis gimbal robot wrist. These equations are used to simulate the rotation of a robot hand by the robot wrist in response to operator rotational velocity commands to the robot hand. Near gimbal lock (wrist singularity), excessive rotational rates occur. Scaling the rates, which is necessary for the three-gimbal robot wrist to prevent rate limiting, introduces an undesirable time delay in the robot hand rotation with respect to the commanded rotation. However, the merit of the four-gimbal robot wrist is that the fourth gimbal angle keeps the robot wrist away from the singularity so that the robot hand moves exactly as commanded. It appears that in a 'worst-type' maneuver of the robot hand, the fourth gimbal angle can be defined so that none of the gimbal angle rates exceed about twice the commanded rates.

Barker, L. K.↗

NASA NTRS1989

Control of free-flying space robot manipulator systems

Control techniques for self-contained, autonomous free-flying space robots are being tested and developed. Free-flying space robots are envisioned as a key element of any successful long term presence in space. These robots must be capable of performing the assembly, maintenance, and inspection, and repair tasks that currently require astronaut extra-vehicular activity (EVA). Use of robots will provide economic savings as well as improved astronaut safety by reducing and in many cases, eliminating the need for human EVA. The focus of the work is to develop and carry out a set of research projects using laboratory models of satellite robots. These devices use air-cushion-vehicle (ACV) technology to simulate in two dimensions the drag-free, zero-g conditions of space. Current work is divided into six major projects or research areas. Fixed-base cooperative manipulation work represents our initial entry into multiple arm cooperation and high-level control with a sophisticated user interface. The floating-base cooperative manipulation project strives to transfer some of the technologies developed in the fixed-base work onto a floating base. The global control and navigation experiment seeks to demonstrate simultaneous control of the robot manipulators and the robot base position so that tasks can be accomplished while the base is undergoing a controlled motion. The multiple-vehicle cooperation project's goal is to demonstrate multiple free-floating robots working in teams to carry out tasks too difficult or complex for a single robot to perform. The Location Enhancement Arm Push-off (LEAP) activity's goal is to provide a viable alternative to expendable gas thrusters for vehicle propulsion wherein the robot uses its manipulators to throw itself from place to place. Because the successful execution of the LEAP technique requires an accurate model of the robot and payload mass properties, it was deemed an attractive testbed for adaptive control technology.

Cannon, Robert H., Jr.↗

NASA NTRS1987

Motion coordination and programmable teleoperation between two industrial robots

Tasks for two coordinated industrial robots always bring the robots in contact with a same object. The motion coordination among the robots and the object must be maintained all the time. To plan the coordinated tasks, only one robot's motion is planned according to the required motion of the object. The motion of the second robot is to follow the first one as specified by a set of holonomic equality constraints at every time instant. If any modification of the object's motion is needed in real-time, only the first robot's motion has to be modified accordingly in real-time. The modification for the second robot is done implicitly through the constraint conditions. Thus the operation is simplified. If the object is physically removed, the second robot still continually follows the first one through the constraint conditions. If the first robot is maneuvered through either the teach pendant or the keyboard, the second one moves accordingly to form the teleoperation which is linked through the software programming. Obviously, the second robot does not need to duplicate the first robot's motion. The programming of the constraints specifies their relative motions.

Luh, J. Y. S.↗

NASA NTRS1991

Effect of motor dynamics on nonlinear feedback robot arm control

A nonlinear feedback robot controller that incorporates the robot manipulator dynamics and the robot joint motor dynamics is proposed. The manipulator dynamics and the motor dynamics are coupled to obtain a third-order-dynamic model, and differential geometric control theory is applied to produce a linearized and decoupled robot controller. The derived robot controller operates in the robot task space, thus eliminating the need for decomposition of motion commands into robot joint space commands. Computer simulations are performed to verify the feasibility of the proposed robot controller. The controller is further experimentally evaluated on the PUMA 560 robot arm. The experiments show that the proposed controller produces good trajectory tracking performances and is robust in the presence of model inaccuracies. Compared with a nonlinear feedback robot controller based on the manipulator dynamics only, the proposed robot controller yields conspicuously improved performance.

Tarn, Tzyh-Jong↗

NASA NTRS1992

Cooperative intelligent robotics in space III; Proceedings of the Meeting, Boston, MA, Nov. 16-18, 1992

The present volume on cooperative intelligent robotics in space discusses sensing and perception, Space Station Freedom robotics, cooperative human/intelligent robot teams, and intelligent space robotics. Attention is given to space robotics reasoning and control, ground-based space applications, intelligent space robotics architectures, free-flying orbital space robotics, and cooperative intelligent robotics in space exploration. Topics addressed include proportional proximity sensing for telerobots using coherent lasar radar, ground operation of the mobile servicing system on Space Station Freedom, teleprogramming a cooperative space robotic workcell for space stations, and knowledge-based task planning for the special-purpose dextrous manipulator. Also discussed are dimensions of complexity in learning from interactive instruction, an overview of the dynamic predictive architecture for robotic assistants, recent developments at the Goddard engineering testbed, and parallel fault-tolerant robot control.

Erickson, Jon D.↗

NASA NTRS1994

Meeting the challenges of installing a mobile robotic system

The challenges of integrating a mobile robotic system into an application environment are many. Most problems inherent to installing the mobile robotic system fall into one of three categories: (1) the physical environment - location(s) where, and conditions under which, the mobile robotic system will work; (2) the technological environment - external equipment with which the mobile robotic system will interact; and (3) the human environment - personnel who will operate and interact with the mobile robotic system. The successful integration of a mobile robotic system into these three types of application environment requires more than a good pair of pliers. The tools for this job include: careful planning, accurate measurement data (as-built drawings), complete technical data of systems to be interfaced, sufficient time and attention of key personnel for training on how to operate and program the robot, on-site access during installation, and a thorough understanding and appreciation - by all concerned - of the mobile robotic system's role in the security mission at the site, as well as the machine's capabilities and limitations. Patience, luck, and a sense of humor are also useful tools to keep handy during a mobile robotic system installation. This paper will discuss some specific examples of problems in each of three categories, and explore approaches to solving these problems. The discussion will draw from the author's experience with on-site installations of mobile robotic systems in various applications. Most of the information discussed in this paper has come directly from knowledge learned during installations of Cybermotion's SR2 security robots. A large part of the discussion will apply to any vehicle with a drive system, collision avoidance, and navigation sensors, which is, of course, what makes a vehicle autonomous. And it is with these sensors and a drive system that the installer must become familiar in order to foresee potential trouble areas in the physical, technical, and human environment.

Decorte, Celeste↗

NASA NTRS1995

Hazardous materials emergency response mobile robot

A simple or unsophisticated robot incapable of effecting straight-line motion at the end of its arm is presented. This robot inserts a key held in its end effector or hand into a door lock with nearly straight-line motion by gently thrusting its back heels downwardly so that it pivots forwardly on its front toes while holding its arm stationary. The relatively slight arc traveled by the robot's hand is compensated by a complaint tool with which the robot hand grips the door key. A visible beam is projected through the axis of the hand or gripper on the robot arm end at an angle to the general direction in which the robot thrusts the gripper forward. As the robot hand approaches a target surface, a video camera on the robot wrist watches the beam spot on the target surface fall from a height proportional to the distance between the robot hand and the target surface until the beam spot is nearly aligned with the top of the robot hand. Holes in the front face of the hand are connected through internal passages inside the arm to an on-board chemical sensor. Full rotation of the hand or gripper about the robot arm's wrist is made possible by slip rings in the wrist which permit passage of the gases taken in through the nose holes in the front of the hand through the wrist regardless of the rotational orientation of the wrist.

Stone, Henry W.↗

NASA NTRS2000

Robotic Precursor Missions for Mars Habitats

Infrastructure support for robotic colonies, manned Mars habitat, and/or robotic exploration of planetary surfaces will need to rely on the field deployment of multiple robust robots. This support includes such tasks as the deployment and servicing of power systems and ISRU generators, construction of beaconed roadways, and the site preparation and deployment of manned habitat modules. The current level of autonomy of planetary rovers such as Sojourner will need to be greatly enhanced for these types of operations. In addition, single robotic platforms will not be capable of complicated construction scenarios. Precursor robotic missions to Mars that involve teams of multiple cooperating robots to accomplish some of these tasks is a cost effective solution to the possible long timeline necessary for the deployment of a manned habitat. Ongoing work at JPL under the Mars Outpost Program in the area of robot colonies is investigating many of the technology developments necessary for such an ambitious undertaking. Some of the issues that are being addressed include behavior-based control systems for multiple cooperating robots (CAMPOUT), development of autonomous robotic systems for the rescue/repair of trapped or disabled robots, and the design and development of robotic platforms for construction tasks such as material transport and surface clearing.

Huntsberger, Terry↗

NASA NTRS2012

Automatic control system generation for robot design validation

The specification and drawings present a new method, system and software product for and apparatus for generating a robotic validation system for a robot design. The robotic validation system for the robot design of a robotic system is automatically generated by converting a robot design into a generic robotic description using a predetermined format, then generating a control system from the generic robotic description and finally updating robot design parameters of the robotic system with an analysis tool using both the generic robot description and the control system.

Bacon, James A.↗

DOE OSTI2026

Synthetic Digital Environments for Training Robots on Earth & Beyond [Poster]

Creating physical replicas of real-world environments to train robots for challenging outdoor tasks, whether constructing energy infrastructure like solar farms on Earth or on the Moon and Mars, is prohibitively expensive. This project will prototype a high-fidelity digital twin framework using NVIDIA IsaacSim to create realistic digital representations of robotic systems and their operating conditions, including varied terrains and environmental factors, allowing robots to learn and adapt in a faster, safer, and more affordable way to tackle unpredictable challenges in terrestrial and extraterrestrial applications. The Robotic Space Exploration (RoSE) Lab at Colorado School of Mines focused on the development and testing of synthetic digital twins to explore multi-physics interactions between robots and unstructured environments, with emphasis on lunar conditions such as deformable regolith, reduced gravity, and terrain-robot contact dynamics. The Industrialized Construction Innovation (ICI) team at National laboratory of the Rockies (NLR), simulated robotic apparatus and construction workflows using synthetic digital twins to inform real-world deployment, targeting application-driven use cases such as robotic construction of a scaled prototype of a photovoltaic energy infrastructure. Joint efforts between RoSE and ICI are continuing to explore how environment-scale multi-physics modeling and application-level robotic system simulation could be integrated to support robotic construction of energy infrastructure in highly unstructured environments, including scenarios relevant to the Lunar South Pole.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗

NASA NTRSDate not supplied

Astrobee: Completed, Current, and Future Research using Free Flying Robots on the International Space Station

After four years on the International Space Station (ISS), the Astrobee Research Facility, has completed over 130 Test Sessions logging over 1000 hours of operations. Managed by the NASA ISS Program OZ office and supported by NASA Ames Research Center (ARC) in California, the Astrobee Team maintains three identical free-flying Astrobee robots for research on the ISS. As a technology demonstration platform, the Astrobee Robots are available for Guest Scientists to use for a spectrum of research capabilities. Astrobee, propelled by battery-operated fans, is designed to autonomously operate throughout most of the USOS (US Orbital Segment), with the objective of minimizing astronaut support. Astrobee carries a suite of six cameras, a two degree-of-freedom (DOF) arm with a gripper that can grasp ISS handrails and other objects, and three payload bays that provide power and data for guest science hardware. Astrobee can autonomously execute hours-long flight plans or be teleoperated from the ground or by astronauts. While the Astrobee Team continues to improve mapping and autonomous flight capabilities, one of the main goals of Astrobee Robots is to provide research opportunities for Guest Scientists. The Astrobee Robot Software (ARS) makes extensive use of the open-source Robot Operating System (ROS). The ARS can be used interchangeably with an Astrobee Simulator or as Astrobee’s onboard software. ARS features include autonomous docking and perching, real-time teleoperations from the ground, plan based autonomous tasks, multi Astrobee communication, among other capabilities. Through simulation software and ground testing laboratories, the Astrobee Team is available to support Guest Scientists during development and testing and lead real-time ISS operations. Guest Scientists can participate in this research opportunity following the Guest Science Lifecycle (GSL) shown in Figure 1: Guest Science Lifecycle below. The Astrobee Team and Guest Scientists have complete research including Gecko materials studies, RFID and sound sensing capabilities, student Robotics Programming Challenges, and Free Flyer formation flight investigations. Current science with the Astrobee Robots includes Free Flyer self-toss studies, new docking capabilities, advanced mapping resolution capabilities, and high resolution panoramic imagery. Future Guest scientists and Astrobee Team research will focus on robotics applications for future NASA missions such as Gateway and Artemis and potential experiments involving human-robot interactions. This presentation will focus on four main subjects, 1) completed, current, and future planned research using the Astrobee robots, 2) how Guest Scientist get from conception to the ISS, 3) Astrobee Facility resources available for Guest Science ground testing and real-time ISS operations support, and 4) lessons learned from four years of ISS operations.

Astrobee↗

DOE OSTI2018

Adaptation of Commercially Available Robots for Conditioning and Packaging ILW at Sellafield - 18282

The Legacy Ponds and Silos at Sellafield site contain some of the most hazardous Intermediate Level Waste (ILW) in the UK. As part of a multi-billion pound decommissioning programme, this waste will be retrieved and transported across the site for conditioning and packaging in the Box Encapsulation Plant (BEP). Current plans are to commence plant active commissioning in 2022, which will represent a major milestone in the UK nuclear decommissioning programme. Within the plant, skips of waste will be transferred from the shielded transport package into standard 3 cubic metre ILW containers. Waste from the Pile Fuel Storage Pond and First Generation Magnox Storage Pond will be immobilised in cementitious grout before being transferred to an adjacent store. Waste from the Magnox Swarf Storage Silo will not be immobilised in grout, but will be packaged, providing multi-barrier containment. During the concept design, the project team selected commercially available robots as the most viable technology for carrying out the numerous dexterous and repetitive tasks involved in characterising, conditioning and packaging the waste within the shielded 'hot' cells. Significant technical challenges had to be overcome during the design to adapt a commercially available robot for use within a high radiation / high contamination environment, where human access is not safe even for short periods of time. These challenges included: - Designing robot assemblies that could be retrofitted into the existing cell structure that was constructed as part of an earlier project but never completed; - Designing robot assemblies that could be recovered to their 'transport' position without requiring manual intervention; - Designing robot assemblies that could be remotely removed and replaced with new ones if they failed part way through the plant operational life; - Designing through-wall service and power connections that allow maintenance and recovery; - Designing control systems and human-machine interfaces that enable both manual and automated operation of the robot, whilst avoiding collisions with the in-cell cranes and other in cell furniture; - Assessing the radiation tolerance of all items. Bespoke computer simulations and full-scale development trials have been carried out, using non-active test materials, in order to demonstrate the Technology Readiness Level (TRL) required by Sellafield Limited (SL) at each stage of the project [1]. The results of these trials have been recorded in both video and written form so that they can form part of the project's Knowledge Management database. Detailed designs and specifications for the robot assemblies have been updated to incorporate the recommendations from the development trials. Procurement and manufacture of robot assemblies has already commenced to deliver two waste handling robots, two waste container lidding / swabbing robots and associated critical spares. (authors)

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