Engineering topics
Publications and source records attributed to Matthew Mahlin.
The Tall Lunar Tower (TLT) In-Space Assembly (ISA) team aims to design, model, fabricate, autonomously assemble, and characterize a TLT engineering development unit (EDU). The autonomous assembly of a tower also demonstrates a cross-cutting technology that can be applied to other lunar structures, such as blast shields, radiation shelters, and safe havens.
Explore the source record for details and available documents.
Towers are an efficient structure commonly used to elevate systems against a gravity field, such as above the surface of a planet or the Moon. Towers can be used to elevate antennas, transmitters and sensors for communication, navigation, and observation infrastructure in support of surface operations. Near the Lunar poles, elevation of rotating solar panels enables nearly continuous panel illumination for solar power production despite the Sun remaining near the horizon year-round. Further, once technology is developed for tower assembly, this same technology can be extended to the assembly of a variety of structures including rocket blast containment shields, bridges, shelters, and habitats from either Earth-sourced or Lunar-sourced structural members. Environmental factors on the Lunar surface are vastly different than those found on Earth and have significant impact on the design of towers. Towers designed for the Lunar surface have no heritage nor Earth analog. The designs discussed herein are therefore breaking new ground creating a fundamentally new class of structures outside of current experience and intuition. The purpose of this paper is to: a) describe the unique environmental factors affecting tower design on the Lunar surface compared to Earth-based systems, b) evaluate two structural forms for the tower; telescoping tubes and an assembled truss, as well as c)provide recommendations on when each structural form is most suitable. A major contribution presented in the current paper is to provide parametric plots and supporting equations of mass and volume versus module power level and blanket height above the Lunar surface for the solar array application, to enable system level studies of optimum power module distribution and size. A secondary contribution are plots of the mass and volume of aluminum or structural glass required for assembled truss towers formed from Lunar derived structural members. An objective of achieving 1 MW of total power has been used to enable comparison of structural forms, because the total mass of solar arrays is consistent. It will be shown that for moderate module sizes, up to ~50 kW power modules, based on a telescoping tube tower have advantages, but for power modules from 50 kW to 200 kW an assembled truss tower can be created with half to one third of the tube tower mass. More significantly, when shipped from Earth, an assembled truss tower can be packed into 1/14th to 1/25th of the tube tower volume. Truss designs in the 100 kW to 200 kW range will be shown to be a favorable when assembled from either graphite-epoxy angles shipped from Earth or aluminum angles fabricated from Lunar materials. 50 kW towers are an attractive choice for both a telescoping or assembled tower with the solar arrays elevated 10 m above the Lunar surface, while increased solar array elevation favors 100 kW to 200 kW power modules.
The Tall Lunar Tower (TLT) project developed a robotic tower assembly system (RTAS) and TLT Truss engineering development units (EDUs) to perform a ground demonstration of supervised semi-autonomous robotic assembly of a truss-based tall tower. Truss structures provide exceptional strength-to-weight ratios for payload capabilities supporting large masses. On the lunar surface, tall towers are a critical structural system that will enable significant solar power generation by supporting vertical solar arrays and beyond-the-horizon communications at the lunar south pole, supporting the Artemis mission architecture, as well as a lunar economy. Tall towers, greater than 30-meters-tall, provide the elevation needed for more consistent solar power generation due to low inclination sunlight and deep shadowing from surface features on the lunar surface at the poles. The robotic structural assembly technologies developed for truss-based tall towers will also enable other large-scale functional lunar structures to be built, including launch plume deflectors, lunar safe havens for astronauts and assets, surface transportation for cargo, and other critical infrastructure. Robotic assembly of truss structures for lunar surface infrastructure is near-term enabling for future Artemis mission campaign and Moon to Mars Objectives needs for power and communication. The project team designed, fabricated, tested, and demonstrated the RTAS EDU by assembling a TLT Truss EDU in a laboratory environment. The hardware systems and the supervised semi-autonomous assembly process for a TLT assembled EDU design, along with descriptions of a hardware demonstration are presented.
In-space joining technologies are crucial for stimulating an in-space economy and for enabling sustained space exploration by in-space manufacturing and repair of metallic structures. Compared to brazing or soldering, in-space welding (ISW) can provide highly hermetic, strong, and complex joints, potentially without introducing additional material. However, the influence of extreme temperatures, reduced pressure, and reduced gravity on ISW is not yet fully elucidated. Several efforts at NASA are investigating laser beam welding (LBW) as a joining and repair method in both thermal vacuum (TVAC) and combined vacuum & reduced gravity environments. NASA Marshall Space Flight Center (MSFC) shepherded several ISW projects in its past, including the 1973 electron beam welding on Skylab, the 1989 low-power LBW on parabolic flights, and the unflown 1990s-era In-Space Welding Experiment. Recent parabolic flights and 3 degree-of-freedom ground testing build upon this heritage. A collaboration with the Ohio State University using NASA Langley Research Center (LaRC) hardware retrofitted for LBW achieved the first high-powered laser welds under vacuum and low gravity and developed a workforce capable developing such experimental hardware. A ground testing campaign at the MSFC Flat Floor simulated fit-up and welding representative of ISW in 3 degrees of freedom to emulate microgravity effects on inertial systems. One ongoing effort is a NASA Early Career Initiative project – Lunar Assembly and Servicing by Autonomous Robotics (LASAR). Ruggedized LBW components were developed by an external partner for use in TVAC. A TVAC-rated robotic arm was procured by MSFC and used in the first known robotic laser weld where all components save the laser generator were under vacuum. NASA Johnson Space Center (JSC) is advancing supervised autonomy of ISW. NASA LaRC continues to adapt their unique snowflake joint geometry, suitable for connecting segments in trusses and other structures, to LBW. Upcoming TVAC campaigns will focus on testing extreme temperatures, proving out autonomous operations, and demonstrating weld repair. Weld inspection will occur via a non-contact nondestructive evaluation (NDE) technique – electromagnetic acoustic transduction (EMAT). Another ongoing effort based at MSFC is the DISCMAN -- DIsk-Shaped Configurable and Modular vAcuum uNit – which seeks to development a compact, modular payload that can provide a vacuum environment while in a reduced gravity condition. This payload could support multiple in-space manufacturing developmental efforts, with the first demonstration technology being LBW. Currently, the design is targeting operations in the pressurized volume of a space station, but the payload could readily be adapted to other flight platforms such as parabolic or even suborbital vehicles. LASAR elucidates the effects of temperature and vacuum on LBW while DISCMAN probes those of vacuum and gravity. Through these complementary efforts, NASA is addressing the primary challenges of ISW across the space environment while simultaneously developing and maturing technologies including robotic systems and inspection methodologies for future practical implementation on the Moon and beyond. This approach is timely, as upcoming missions requiring sustained human presence in space will depend on reliable ISW capabilities to create robust metallic joints currently unproven in the space environment and to perform repairs in situ .