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Robot Manipulators

Space Shuttle's Remote Manipulator System (Canadarm) is a 50 foot robot arm used to deploy, retrieve or repair satellites in orbit. Initial spinoff version is designed to remove, inspect and replace large components of Ontario Hydro's CANDU nuclear reactors, which supply 50 percent of Ontario Hydro's total power reduction. CANDU robot is the first of SPAR's Remote Manipulator Systems intended for remote materials handling operations in nuclear servicing, chemical processing, smelting and manufacturing. Inco Limited used remote manipulator for remote control mining equipment to enhance safety and productivity of Inco's hardrock mining operations. System not only improves safety in a hazardous operation that costs more than a score of lives annually, it also increases productivity fourfold. Remote Manipulator System Division is also manufacturing a line of industrial robots and developing additional system for nuclear servicing, mining, defense and space operations.

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Colossal Tooling Design: 3D Simulation for Ergonomic Analysis

The application of high-level 3D simulation software to the design phase of colossal mandrel tooling for composite aerospace fuel tanks was accomplished to discover and resolve safety and human engineering problems. The analyses were conducted to determine safety, ergonomic and human engineering aspects of the disassembly process of the fuel tank composite shell mandrel. Three-dimensional graphics high-level software, incorporating various ergonomic analysis algorithms, was utilized to determine if the process was within safety and health boundaries for the workers carrying out these tasks. In addition, the graphical software was extremely helpful in the identification of material handling equipment and devices for the mandrel tooling assembly/disassembly process.

Hunter, Steve L.

A High-Sensitivity Broad-Band Seismic Sensor for Shallow Seismic Sounding of the Lunar Regolith

The recently undertaken Space Exploration Initiative has prompted a renewed interest in techniques for characterizing the surface and shallow subsurface (0-10s of meters depth) of the Moon. There are several reasons for this: First, there is an intrinsic scientific interest in the subsurface structure. For example the stratigraphy, depth to bedrock, density/porosity, and block size distribution all have implications for the formation of, and geological processes affecting the surface, such as sequential crater ejecta deposition, impact gardening, and seismic settling. In some permanently shadowed craters there may be ice deposits just below the surface. Second, the geotechnical properties of the lunar surface layers are of keen interest to future mission planners. Regolith thickness, strength, density, grain size and compaction will affect construction of exploration infrastructure in terms of foundation strength and stability, ease of excavation, radiation shielding effectiveness, as well as raw material handling and processing techniques for resource extraction.

Pike, W. Thomas

Enabling Interoperable Space Robots With the Joint Technical Architecture for Robotic Systems (JTARS)

Robots that operate independently of one another will not be adequate to accomplish the future exploration tasks of long-distance autonomous navigation, habitat construction, resource discovery, and material handling. Such activities will require that systems widely share information, plan and divide complex tasks, share common resources, and physically cooperate to manipulate objects. Recognizing the need for interoperable robots to accomplish the new exploration initiative, NASA s Office of Exploration Systems Research & Technology recently funded the development of the Joint Technical Architecture for Robotic Systems (JTARS). JTARS charter is to identify the interface standards necessary to achieve interoperability among space robots. A JTARS working group (JTARS-WG) has been established comprising recognized leaders in the field of space robotics including representatives from seven NASA centers along with academia and private industry. The working group s early accomplishments include addressing key issues required for interoperability, defining which systems are within the project s scope, and framing the JTARS manuals around classes of robotic systems.

Bradley, Arthur

An Integrated Fault Tolerant Robotic Controller System for High Reliability and Safety

This paper describes the concepts and features of a fault-tolerant intelligent robotic control system being developed for applications that require high dependability (reliability, availability, and safety). The system consists of two major elements: a fault-tolerant controller and an operator workstation. The fault-tolerant controller uses a strategy which allows for detection and recovery of hardware, operating system, and application software failures.The fault-tolerant controller can be used by itself in a wide variety of applications in industry, process control, and communications. The controller in combination with the operator workstation can be applied to robotic applications such as spaceborne extravehicular activities, hazardous materials handling, inspection and maintenance of high value items (e.g., space vehicles, reactor internals, or aircraft), medicine, and other tasks where a robot system failure poses a significant risk to life or property.

robotics fault-tolerant control systems

NASA Lunar Mining and Construction Activities and Plans

The Space Exploration Policy enacted by the US Congress in 2005 calls for the US National Aeronautics and Space Administration (NASA) to implement a sustained and affordable human and robotic program to explore the solar system and beyond; Extend human presence across the solar system, starting with a human return to the Moon by the year 2020, in preparation for human exploration of Mars and other destinations; Develop the innovative technologies, knowledge, and infrastructures both to explore and to support decisions about the destinations for human exploration; and Promote international and commercial participation in exploration to further U.S. scientific, security, and economic interests. In 2006, NASA released the Lunar Architecture Study, which proposed establishing a lunar Outpost on the Moon with international participation to extend human presence beyond Earth's orbit, pursue scientific activities, use the Moon to prepare for future human missions to Mars, and expand Earth s economic sphere. The establishment of sustained human presence on the Moon for science and exploration combines the design, integration, and operation challenges experienced from both the short Apollo lunar missions and the build-up and sustained crew operations of the International Space Station (ISS). Apollo experience reminds developers and mission planners that hardware must operate under extremely harsh environmental and abrasive conditions and every kilogram of mass and payload must be critical to achieve the mission s objectives due to the difficulty and cost of reaching the lunar surface. Experience from the ISS reminds developers and mission planners that integration of all hardware must be designed and planned from the start of the program, operations and evolution of capabilities on a continuous basis are important, and long-term life-cycle costs and logistical needs are equally or more important than minimizing early development and test costs. Overarching all of this is the need to implement efforts that are sustainable and affordable. One area NASA is developing that can significantly change how systems required for sustained human presence are designed and integrated, as well as potentially break our reliance on Earth supplied logistics, is In-Situ Resource Utilization (ISRU). ISRU, also known living off the land, involves the extraction and processing of local resources into useful products. In particular, the ability to make propellants, life support consumables, fuel cell reagents, and radiation shielding can significantly reduce the cost, mass, and risk of sustained human activities beyond Earth. Also, the ability to modify the lunar landscape for safer landing, transfer of payloads from the lander an outpost, dust generation mitigation, and infrastructure placement and buildup are also extremely important for long-term lunar operations. While extra-terrestrial excavation, material handling and processing, and site preparation and construction may be new to NASA and other space agencies, there is extensive terrestrial hardware and commercial experience that can be leveraged. This paper will provide an overview of current NASA activities in lunar ISRU mining and construction and how terrestrial experience in these areas are important to achieving the goal of affordable and sustainable human exploration.

Sanders, Gerald B.

EVA Performance Prediction

Astronaut physical performance capabilities in micro gravity EV A or on planetary surfaces when encumbered by a life support suit and debilitated by a long exposure to micro gravity will be less than unencumbered pre flight capabilities. The big question addressed by human factors engineers is: what can the astronaut be expected to do on EVA or when we arrive at a planetary surface? A second question is: what aids to performance will be needed to enhance the human physical capability? These questions are important for a number of reasons. First it is necessary to carry out accurate planning of human physical demands to ensure that time and energy critical tasks can be carried out with confidence. Second it is important that the crew members (and their ground or planetary base monitors) have a realistic picture of their own capabilities, as excessive fatigue can lead to catastrophic failure. Third it is important to design appropriate equipment to enhance human sensory capabilities, locomotion, materials handling and manipulation. The evidence from physiological research points to musculoskeletal, cardiovascular and neurovestibular degradation during long duration exposure to micro gravity . The evidence from the biomechanics laboratory (and the Neutral Buoyancy Laboratory) points to a reduction in range of motion, strength and stamina when encumbered by a pressurized suit. The evidence from a long history of EVAs is that crewmembers are indeed restricted in their physical capabilities. There is a wealth of evidence in the literature on the causes and effects of degraded human performance in the laboratory, in sports and athletics, in industry and in other physically demanding jobs. One approach to this challenge is through biomechanical and performance modeling. Such models must be based on thorough task analysis, reliable human performance data from controlled studies, and functional extrapolations validated in analog contexts. The task analyses currently carried out for EVA activities are based more on extensive domain experience than any formal analytic structure. Conversely, physical task analysis for industrial and structured evidence from training and EV A contexts. Again on earth there is considerable evidence of human performance degradation due to encumbrance and fatigue. These industrial models generally take the form of a discounting equation. The development of performance estimates for space operations, such as timeline predictions for EVA is generally based on specific input from training activity, for example in the NBL or KC135. uniformed services tasks on earth are much more formalized. Human performance data in the space context has two sources: first there is the micro analysis of performance in structured tasks by the space physiology community and second there is the less structured evidence from training and EV A contexts.

Peacock, Brian

NASA's Habitat Demonstration Unit (HDU) Pressurized Excursion Module (PEM) In-Field Demonstration at Desert RATS 2010

This paper describes the construction, assembly, subsystem integration, transportation, and field testing operations associated with the Habitat Demonstration Unit (HDU) Pressurized Excursion Module (PEM) and discusses lessons learned. In a one-year period beginning summer 2009, a tightly scheduled design-develop-build process was utilized by a small NASA "tiger team" to produce the functional HDU-PEM prototype in time to participate in the 2010 Desert Research and Technology Studies (Desert RATS) field campaign. The process required the coordination of multiple teams, subcontractors, facility management and safety staff. It also required a well-choreographed material handling and transportation process to deliver the finished product from the NASA-Johnson Space Center facilities to the remote Arizona desert locations of the field test. Significant findings of this paper include the team s greater understanding of the HDU-PEM s many integration issues and the in-field training the team acquired which will enable the implementation of the next-generation of improvements and development of high-fidelity field operations in a harsh environment. The Desert RATS analog environment is being promoted by NASA as an efficient means to design, build, and integrate multiple technologies in a mission architecture context, with the eventual goal of evolving the technologies into robust flight hardware systems. The HDU-PEM in-field demonstration at Desert RATS 2010 provided a validation process for the integration team, which has already begun to retool for the 2011 field tests that require an adapted architecture.

Tri, Terry O.

Oxygen Extraction from Regolith Using Ionic Liquids

An important concern with long-duration manned space travel is the need to furnish enough materials to the vehicle, as well as the crew, for the duration of the mission. By extracting oxygen from the oxides present in regolith, propellant and life support could be supplied to the vehicle and the crew while in space, thereby limiting the amount of supplies needed prior to lift-off. Using a class of compounds known as ionic liquids, we have been able to lower the electrolysis operating temperature from 1600 C (molten oxide electrolysis) to less than 200 C, making this process much more feasible in terms of energy consumption and materials handling. To make this process ready for deployment into space, we have investigated what steps of the process would be affected by the low-gravity environment in space. In the lab, the solubilization of lunar regolith simulant in ionic liquid produces water vapor that is normally distilled out of solution and subsequently electrolyzed for oxygen production. This distillation is not possible in space, so we have tested a method known as pervaporation and have suggested a way this technique could be incorporated into a reactor design.

Barrios, Elizabeth A.

Polymers Advance Heat Management Materials for Vehicles

For 6 years prior to the retirement of the Space Shuttle Program, the shuttles carried an onboard repair kit with a tool for emergency use: two tubes of NOAX, or "good goo," as some people called it. NOAX flew on all 22 flights following the Columbia accident, and was designed to repair damage that occurred on the exterior of the shuttle. Bill McMahon, a structural materials engineer at Marshall Space Flight Center says NASA needed a solution for the widest range of possible damage to the shuttle s exterior thermal protection system. "NASA looked at several options in early 2004 and decided on a sealant. Ultimately, NOAX performed the best and was selected," he says. To prove NOAX would work effectively required hundreds of samples manufactured at Marshall and Johnson, and a concerted effort from various NASA field centers. Johnson Space Center provided programmatic leadership, testing, tools, and crew training; Glenn Research Center provided materials analysis; Langley Research Center provided test support and led an effort to perform large patch repairs; Ames Research Center provided additional testing; and Marshall provided further testing and the site of NOAX manufacturing. Although the sealant never had to be used in an emergency situation, it was tested by astronauts on samples of reinforced carbon-carbon (RCC) during two shuttle missions. (RCC is the thermal material on areas of the shuttle that experience the most heat, such as the nose cone and wing leading edges.) The material handled well on orbit, and tests showed the NOAX patch held up well on RCC.

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In Situ Solid Particle Generator

Particle seeding is a key diagnostic component of filter testing and flow imaging techniques. Typical particle generators rely on pressurized air or gas sources to propel the particles into the flow field. Other techniques involve liquid droplet atomizers. These conventional techniques have drawbacks that include challenging access to the flow field, flow and pressure disturbances to the investigated flow, and they are prohibitive in high-temperature, non-standard, extreme, and closed-system flow conditions and environments. In this concept, the particles are supplied directly within a flow environment. A particle sample cartridge containing the particles is positioned somewhere inside the flow field. The particles are ejected into the flow by mechanical brush/wiper feeding and sieving that takes place within the cartridge chamber. Some aspects of this concept are based on established material handling techniques, but they have not been used previously in the current configuration, in combination with flow seeding concepts, and in the current operational mode. Unlike other particle generation methods, this concept has control over the particle size range ejected, breaks up agglomerates, and is gravity-independent. This makes this device useful for testing in microgravity environments.

Agui, Juan H.

NASA Tech Briefs, August 2013

Topics covered include: Radial Internal Material Handling System (RIMS) for Circular Habitat Volumes; Conical Seat Shut-Off Valve; Impact-Actuated Digging Tool for Lunar Excavation; Flexible Mechanical Conveyors for Regolith Extraction and Transport; Remote Memory Access Protocol Target Node Intellectual Property; Soft Decision Analyzer; Distributed Prognostics and Health Management with a Wireless Network Architecture; Minimal Power Latch for Single-Slope ADCs; Bismuth Passivation Technique for High-Resolution X-Ray Detectors; High-Strength, Super-elastic Compounds; Cu-Cr-Nb-Zr Alloy for Rocket Engines and Other High-Heat- Flux Applications; Microgravity Storage Vessels and Conveying-Line Feeders for Cohesive Regolith; CRUQS: A Miniature Fine Sun Sensor for Nanosatellites; On-Chip Microfluidic Components for In Situ Analysis, Separation, and Detection of Amino Acids; Spectroscopic Determination of Trace Contaminants in High-Purity Oxygen; Method of Separating Oxygen From Spacecraft Cabin Air to Enable Extravehicular Activities; Atomic Force Microscope Mediated Chromatography; Sample Analysis at Mars Instrument Simulator; Access Control of Web- and Java-Based Applications; Tool for Automated Retrieval of Generic Event Tracks (TARGET); Bilayer Protograph Codes for Half-Duplex Relay Channels; Influence of Computational Drop Representation in LES of a Droplet-Laden Mixing Layer.

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Electromagnetic Pumps for Conductive-Propellant Feed Systems

Prototype electromagnetic pumps for use with lithium and bismuth propellants were constructed and tested. Such pumps may be used to pressurize future electric propulsion liquid metal feed systems, with the primary advantages being the compactness and simplicity versus alternative pressurization technologies. Design details for two different pumps are described: the first was designed to withstand (highly corrosive) lithium propellant, and t he second was designed to tolerate the high temperature required to pump liquid bismuth. Both qualitative and quantitative test results are presented. Open-loop tests demonstrated the capability of each device to electromagnetically pump its design propellant (lithium or bismuth). A second set of tests accurately quantified the pump pressure developed as a function of current. These experiments, which utilized a more easily handled material (gallium), demonstrated continuously-adjustable pump pressure levels ranging from 0-100 Torr for corresponding input current levels of 0-75 A. While the analysis and testing in this study specifically targeted lithium and bismuth propellants, the underlying design principles should be useful in implementing liquid metal pumps in any conductive-propellant feed system.

Markusic, Thomas E.

Grain Shape Characterization as an Enabling Capability for Lunar Surface Technologies

Lunar regolith has unique physical and geotechnical properties compared with familiar granular materials on Earth, and most lunar simulants as well. Specifically, the cohesion, angle of repose, and compressibility are much higher, and flowability is much lower for lunar regolith than otherwise similar terrestrial-derived materials[1,2]. There is confusion in the literature about the relative importance of vacuum, gravity, and inherent grain characteristics in driving these differences. Here we emphasize the importance of characterizing grain types and shapes for designing and test-ing lunar surface technologies, including for rover mobility, material handling, soil sampling, and heat transfer analyses. We demonstrate laboratory capabilities and preliminary studies, and outline further work to better characterize and simulate lunar grains to reduce risks for surface activities

K. M. Cannon

Suborbital Lunar Gravity Experiment of an Electrodynamic Regolith Conveyor

NASA’s Swamp Works Electrostatics and Surface Physics Laboratory (ESPL) is planning to test a 4-phase electrodynamic regolith conveyor in simulated lunar gravity on a suborbital flight in 2023. A 4-phase electrodynamic regolith conveyor could convey regolith without the risk of rotating or vibratory actuation, which could jam or require regular maintenance due to the abrasive nature of lunar regolith. Another advantage of electrodynamic conveying is the reduction of conveying power, which is important considering the limited scale of available early-stage lunar power systems. The current state of the art(SOA) for lunar regolith conveying is based on recent NASA system studies for oxygen production plants. These plant designs require conveying rates around 100 kg/hr, to produce 10 mT/yr of oxygen from the regolith. To accomplish this, conventional augers and vibratory spiral conveyors have been identified as the SOA or the leading candidates due to their extensive use in the terrestrial material handling industry. At NASA KSC, the use of dynamic electric fields, generated by alternating high voltage on electrodes, has been developed as a dust mitigation solution known as the Electrodynamic Dust Shield (EDS). The EDS is being developed for lenses, solar panels, radiators, fabric and seals. ESPL researchers have shown the ability to move thin layers (~ a few mm) of dust with mW of power. In Academia, researchers have shown the ability to electrodynamically convey regolith up to ~1 kg/hr with a4-phase EDS and electromagnetically convey particles that would suggest a lunar regolith conveying rate of ~25 kg/hr. This paper will describe the design and expected operation of a 4-phase electrodynamic regolith conveyor in lunar gravity. This paper will also describe how an electrodynamic conveyor could be scaled for transporting ISRU relevant flow rates.

Aaron D S Olson

Design and Testing of a Prototype Electrodynamic Regolith Conveyor for Lunar ISRU

NASA’s Swamp Works Electrostatics and Surface Physics Laboratory (ESPL) is developing a 4-phaseelectrodynamic regolith conveyor (ERC) that could convey regolith without the risk of rotating or vibratory actuation, which could jam or require regular maintenance due to the abrasive nature of lunar regolith. Another goal of electrodynamic conveying is the reduction of conveying power, which is important considering the limited capacity of early-stage lunar power systems. The current state of the art(SOA) for lunar regolith conveying is based on recent NASA system studies for oxygen production plants. These plant designs require conveying rates around 100 kg/hr, to produce 10 mT/yr of oxygen from the regolith. To accomplish this, conventional augers and vibratory spiral conveyors have been identified as the SOA or the leading candidates due to their extensive use in the terrestrial material handling industry. At NASA KSC, the use of dynamic electric fields, generated by alternating high voltage on electrodes, has been developed as a dust mitigation solution known as the Electrodynamic Dust Shield (EDS). The EDS is being developed for lenses, solar panels, radiators, fabric and seals and is scheduled for a technology demonstration mission on the Moon in 2023. ESPL researchers have shown the ability to move thin layers (~ a few mm) of dust with mW of power. In Academia, researchers have shown the ability to electrodynamically convey regolith up to ~1 kg/hr with a 4-phase EDS and electromagnetically convey particles that would suggest a lunar regolith conveying rate of ~25 kg/hr. This paper will describe the design and testing of a prototype ERC that could scale to support transporting regolith at ISRU relevant flow rates.

Aaron D S Olson

Design and Testing of a Prototype Electrodynamic Regolith Conveyor For Lunar ISRU

NASA’s Kennedy Space Center’s (KSC) Swamp Works Electrostatics and Surface Physics Laboratory (ESPL) is developing a 4-phase Electrodynamic Regolith Conveyor (ERC) that could convey regolith without the risk of rotating or vibratory actuation, which could jam or require regular maintenance due to the abrasive nature of lunar regolith. Another goal of electrodynamic conveying is the reduction of conveying power, which is important considering the limited capacity of early-stage lunar power systems. The current state of the art (SOA) for lunar regolith conveying is based on recent NASA system studies for oxygen production plants. These plant designs require conveying rates around 100 kg/hr, to produce 10 mT/yr of oxygen from the regolith. To accomplish this, conventional augers and vibratory spiral conveyors have been identified as the SOA or the leading candidates due to their extensive use in the terrestrial material handling industry. At NASA KSC, the use of dynamic electric fields, generated by alternating high voltage on electrodes, has been developed as a dust mitigation solution known as the Electrodynamic Dust Shield (EDS). The EDS is being developed for lenses, solar panels, radiators, fabric and seals and is scheduled for a technology demonstration mission on the Moon in 2023. ESPL researchers have shown the ability to move thin layers (a few mm) of dust with mW of power. In Academia, researchers have shown the ability to electrodynamically convey regolith up to 1 kg/hr with a 4-phase EDS. This paper will describe the design and testing of a prototype ERC that could scale to support transporting regolith at ISRU relevant flow rates.

Conveyor

Design and Testing of a Prototype Electrodynamic Regolith Conveyor for Lunar ISRU

NASA’s Kennedy Space Center’s (KSC) Swamp Works Electrostatics and Surface Physics Laboratory (ESPL) is developing a 4-phase Electrodynamic Regolith Conveyor (ERC) that could convey regolith without the risk of rotating or vibratory actuation, which could jam or require regular maintenance due to the abrasive nature of lunar regolith. Another goal of electrodynamic conveying is the reduction of conveying power, which is important considering the limited capacity of early-stage lunar power systems. The current state of the art (SOA) for lunar regolith conveying is based on recent NASA system studies for oxygen production plants. These plant designs require conveying rates around 100 kg/hr, to produce 10 mT/yr of oxygen from the regolith. To accomplish this, conventional augers and vibratory spiral conveyors have been identified as the SOA or the leading candidates due to their extensive use in the terrestrial material handling industry. At NASA KSC, the use of dynamic electric fields, generated by alternating high voltage on electrodes, has been developed as a dust mitigation solution known as the Electrodynamic Dust Shield (EDS). The EDS is being developed for lenses, solar panels, radiators, fabric and seals and is scheduled for a technology demonstration mission on the Moon in 2023. ESPL researchers have shown the ability to move thin layers (a few mm) of dust with mW of power. In Academia, researchers have shown the ability to electrodynamically convey regolith up to 1 kg/hr with a 4-phase EDS. This paper will describe the design and testing of a prototype ERC that could scale to support transporting regolith at ISRU relevant flow rates.

Lunar