Multifunctional End Effector for Regolith Construction, Acquisition, and Transfer (MEERCAT) Flyer
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Publications and source records attributed to Robert P Mueller.
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Kennedy Space Center’s (KSC) Swamp Works, provides government and commercial space ventures with the technologies required for working and living on the surfaces of the Moon or other planets and bodies in our solar system. The Swamp Works team establishes agile, innovative and cost effective exploration mission solutions through leveraging of partnerships across NASA, industry and academia. Concepts start small and build up efficiently, with lean development processes and a hands on approach. Testing is performed in early stages to drive design improvements and progressively increase Technology Readiness Levels (TRL). Swamp Works provides concepts, architecture studies and trades, designs, data, technology development, technology demonstration hardware, flight hardware, testing, flight support and knowledge in support of the development of surface systems. This paper will summarize the state of the art in innovation methods, and it will compare the various other methods to how innovation is accomplished at the NASA KSC Swamp Works. Since 2013, Swamp Works has developed a wide variety of technologies, and has demonstrated viable methods for innovation while also collaborating with other government agencies, industry and academia to support space exploration. These methods focus on agile design, test, build iterations where each cycle of prototyping results in improved knowledge and designs. Failures are tole rated in the early stages of these iterations, since the overall development cycle is shorter more efficient and cost effective by retiring risk early in the cycle. Momentum is maintained and the development teams remain highly motivated by the high level of team work, technical excellence, engagement and creative freedom.
This project designed and fabricated a prototype model of an Umbilical Low Force Disconnect (LFD). Traditional quick disconnects (QD) have a high separation force (SF) when pressurized due to the axial flow path through the QD.
A Pneumatic Sampler (P-SMP)is being provided by Honeybee Robotics with support from NASA Planetary Missions Program Office (PMPO)for JAXA’s Martian Moons eXploration (MMX) mission. The goal of this mission is to closely survey the Martian moons Deimos and Phobos, and then to collect regolith from Phobos and return it to Earth. The P-SMP will be mounted to a leg of the lander and will be responsible for collecting surface regolith alongside the JAXA provide Core Sampler (C-SMP). The Sampling Funnel of the P-SMP utilizes two sets of sampling nozzles: one set of nozzles pointed directly at the surface to kick-up and loft material into the sampling head, and a second set of nozzles to direct the oncoming material into the sample return canister further up the lander leg. A robotic arm mounted underneath the lander will then remove the sample canister and place it inside the sample return capsule for Earth return. Several iterations of the P-Sampler have been designed and tested inside a vacuum chamber with Phobos regolith simulant. In all tests, the P-Sampler successfully acquired the sample, even in an extreme scenario where the sampling head was mounted 10 cm above a surface covered with gravel.
Ensuring the safety of crew and cargo in future human missions to Mars is of critical importance to mission success. On Earth, we do not send people to remote, extreme environments to live for months or years without building safe shelters, landing strips, roads, and necessary infrastructure in advance.
NASA's Centennial Challenges program uses prize competitions with the goal of accelerating innovation in the aerospace industry. Competitions in the Centennial Challenges portfolio have previously focused on advancements in space robotics, regolith excavation, bio-printing, astronaut suit design, small satellites, and solar-powered vehicles. NASA's Three Dimensional (3D) Printed Habitat Centennial Challenge represents a partnership between NASA and the non-profit partner: Bradley University, with co-sponsors Caterpillar, Bechtel, Brick and Mortar Ventures, the American Concrete Institute, and the United States Army Corps of Engineers (USACE) Engineer Research and Development Center (ERDC) to spur development in automated additive construction technologies. The challenge asks teams to design and construct a scaled and simulated Martian habitat using indigenous materials and large scale 3D automated printing systems. Phase 1 of the competition, held in 2015, was an architectural design competition for habitat concepts that could be 3D printed. Phase 2, completed in 2017, asked teams to develop feedstocks from indigenous materials and hydrocarbon polymer recyclables, and demonstrate automated printing systems to manufacture these feedstocks into test specimens to assess mechanical strength. This paper will discuss the Phase 3 competition, focusing on technology outcomes that can potentially be infused into both terrestrial and planetary construction applications. The Phase 3 competition was divided into two sub-competitions: 1) virtual construction, where teams created a high fidelity building information model (BIM) of their 3D-printed habitat design and 2) the construction competition, which required teams to 3D print a structural foundation and subject materials samples to freeze/thaw testing and impact testing (level 1), produce a habitat element and complete a hydrostatic test (level 2), and additively manufacture a 1:3 scale habitat onsite in a head to head competition at Caterpillar, inc.'s Edwards Demonstration & Learning Center near Peoria, Illinois over the course of three days (level 3). While the Phase 2 competition focused primarily on the development of novel feedstocks and robotic printing systems, Phase 3 emphasized the scale-up of these systems and autonomous operation (demonstrating the capability to operate systems on precursor missions prior to the arrival of crew, or terrestrially in field operation settings where human tending of a manufacturing system may be limited). The Phase 3 virtual construction levels yielded a number of novel habitat designs, including both modular habitats and vertically-oriented habitat concepts. The Phase 3 construction competition also challenged teams to autonomously place penetrations and interfacing elements in additively manufactured structures. The paper will emphasize potential applications for the new materials and technologies developed under the umbrella of the competition within NASA's portfolio and in Earth-based applications such as disaster response and infrastructure improvement.
The NASA Centennial Challenges: 3D-Printed Habitat Challenge seeks to develop the fundamental technologies necessary to manufacture an off-world habitat using mission recycled materials and/or local indigenous materials. The vision is that autonomous habitat manufacturing machines will someday be deployed to the Moon or Mars to construct shelters for human habitation. NASA and Bradley University, are holding a new US$ 2.5 million competition to design and build a 3-D printed habitat for deep space exploration, including the agency's journey to Mars. The multi-phase 3-D Printed Habitat Challenge, part of NASA's Centennial Challenges program, is designed to advance the additive construction technology needed to create sustainable housing solutions for Earth and beyond. The first phase of the competition ran through Sept. 27, 2015. This phase, a design competition, called on participants to develop state-of-the-art architectural concepts that take advantage of the unique capabilities 3-D printing offers. The top 3 prizes with a prize purse of $40,000 were awarded at the 2015 World Maker Faire in New York. The second phase of the competition is called the Structural Member Competition and it is divided into three levels happening in the spring and summer of 2017. The Compression Test Competition (Level 1) focuses on the fabrication technologies needed to manufacture structural components from a combination of indigenous materials and recyclables, or indigenous materials alone. For Level 1, teams will develop 3D printable materials, build a 3D printing machine, and print two specimens: a truncated cone and a cylinder. The Level 2 Beam Member Competition is the second of three sub-competitions within the overall Structural Member Competition. For Level 2, teams will print a beam that will be tested. The Level 3 Head to Head Competition is the third of three sub-competitions within the overall Structural Member Competition. For Level 3, teams will develop 3D printable materials, use a 3D printing machine, and print three compression specimens of the elected material, three flexural specimens of the elected material, and one dome structure. Tests conducted on the specimens and the dome structure will determine Level 3 scores and awards. On Earth these same habitat manufacturing capabilities could be used to produce housing wherever affordable housing is needed and access to conventional building materials and skills is limited. Terrestrially, it is envisioned that local indigenous materials (dirt, clay, sand, etc.) could be combined with readily available recyclable materials and used to construct semi-permanent shelters against environmental elements for human habitation. The goal of the 3D-Printed Habitat Challenge is to foster the development of new technologies necessary to additively manufacture a habitat using local indigenous materials with, or without, recyclable materials. This paper will summarize the Level 2 results of this NASA Centennial Challenge competition and it will discuss related technology advancement.
To continue on a sustainable and flexible path, NASA needs to address the challenge of collecting and moving large amounts of regolith at the destination. Acquiring the water resources on Mars will require mining significant quantities of regolith and this is not possible with the state-of-the-art low mass excavation systems. Low gravity environments (Mars = 3/8 G) and launch mass restrictions limit the traction and the resulting reaction force of the vehicle, making current terrestrial techniques impractical. This project addressed this challenge by developing a completely new technology that can mine large quantities of regolith on Mars. Recent measurements by the “Curiosity” rover on Mars have found that the regolith contains ~ 2% water by weight globally, ~4% in Jezero Crater (Human Architecture Team’s reference landing site), and much more at the poles(Leshin et al, 2013). RASSOR 2.0 is a planetary excavator, which has a mass of 66 kg, with a 0.38 kg vehicle mass per kilogram, per hour of excavation rate and power usage of 4 W per kg of regolith excavation rate. A single RASSOR 2.0 can excavate a minimum of 2.7 metric tons of regolith per day.This is accomplished by using counteracting excavation forces on two opposing digging implements called bucket drums and an autonomous mining control system. This work has addressed several major research areas outlined in the NASA Technology Area (TA) 04 Robotics & Autonomous Systems and TA 07 Human Destination Systems roadmaps. This project started at Technology Readiness Level (TRL) 4 as a low fidelity “proof of concept” prototype which has successfully demonstrated basic regolith simulant excavation functionality in a lab-scale gravity off load test. The foundational technology described here was awarded US patent number: US 9027265 for a “Zero horizontal reaction force excavator” on May 12, 2015.
Recent developments around the world show an increased interest and international activity toward developing a lunar surface human and robotic presence with a long term, sustainable vision. In Europe, the construction of a "Moon Village" has been proposed, and China has stated its intention to build a research station with a crew at the lunar South Pole. Russia stated it will land cosmonauts on the Moon in the 2030's. India has sent an orbiter, a robotic lander, and rover to the Moon. The USA intends to land the first woman and a man on the Moon by 2024 to initiate a sustained human lunar presence.A lunar research station with associated commercial activities will require infrastructure to become a permanent capability. Landing and launch pads, propellant storage and distribution farms, spacecraft access and handling structures, cranes, blast protection berms or walls, roads, graded areas, dust stabilized areas, foundations, parking lots, radiation shelters, micro-meteorite protection hangars, habitats and other human shelters, greenhouse farms, utility trenches, power plants, industrial water and oxygen extraction plants, communications antenna towers, thermal protection, mining zones, crater access and sub-surface access will be required to create a safe and sustainable lunar operations capability. This infrastructure will require significant construction activities in an extreme environment, with risky and expensive operations. On Earth, there are similar large and expensive projects (>$1 Billion) in difficult locations that attract a lot of public attention. These are known as "Mega Projects" and examples include bridges, tunnels, highways, railways, airports, seaports, power plants, dams, wastewater projects, Special Economic Zones (SEZ), oil and natural gas extraction projects, public buildings, information technology systems, aerospace projects, and weapons systems. Large consortiums consisting of public and private entities typically implement these infrastructure Mega-Projects.This paper will compare the typical design process, project management process, and work flow in the terrestrial construction industry to the space industry in order to create a better understanding between the terrestrial construction industry and the space industry, to further enable collaboration on a lunar Mega Project to build infrastructure on the Moon. In addition, a glossary of respective industry terminology with annotated linkages and definitions has been compiled. This information will enable contracts and business practices to be formulated for generating requests for proposals (RFP) by governments to consortiums consisting of construction and space industry companies that will bid on Lunar Infrastructure Projects that could lead to contracts to build the permanent capabilities.
Space Mining for resources such as water ice, and regolith, which contain many elements in the form of metals, minerals, volatiles and other compounds, is a necessary step for In-Situ Space Resource Utilization (ISRU). One of the primary goals is to extract propellants from the regolith and water ice, such as oxygen and hydrogen which could then be used for in-space transportation. In addition, the space mining system can be used for various construction tasks that can benefit human and robotic exploration as well as scientific investigations based on excavated exposed topography, such as the side walls of trenches. The National Aeronautics & Space Administration (NASA) "Lunabotics" Robotic Mining Competition (RMC) is a university-level competition designed to engage and retain students in science, technology, engineering and mathematics (STEM). NASA has directly benefited from the competition by encouraging the development of innovative lunar excavation concepts from universities which has resulted in clever ideas and solutions which could be applied to an actual lunar excavation device or payload. The challenge is for students to design and build a remote controlled or autonomous excavator, called a "lunabot", which can collect and deposit a minimum of 10 kilograms of lunar simulant within 15 minutes. In recent years the goal has been changed to excavate a minimum of 1 kg of simulated icy regolith which is found under an overburden of regolith simulant. The complexities of the challenge include the abrasive characteristics of the lunar regolith simulant, the weight and size limitations of the lunabot, and the ability to control the lunabot from a remote-control center or operate it autonomously. This paper will present the results of the ten Lunabotics Robotic Mining Competitions held between May 2010 and May 2019. Each year over 50 university teams have attended, resulting in over 500 lunabot designs and subsequent prototypes. Over 6,000 university students have been part of the on-site competition at KSC. Even more students and the public were engaged via internet broadcasting and social networking media. The various designs have been cataloged and categorized here to provide information to future Lunabotics RMC mining robot designers and competitors. Categories will focus on both the mechanical design as well as the autonomy architecture/design. It is also expected to be of value for actual future space missions, as knowledge is gained from testing many innovative prototypes in simulated lunar regolith. A taxonomy of robotic excavator designs has been presented. In addition, the paper will discuss changes in learning paradigms occurring in the current generation of students, and how this competition leverages those changes to challenge students to develop skills in graduate level concepts and apply them. Examples of how this translates to hiring opportunities for commercial sponsors has also been discussed.
The human species has a yearning for exploration as evidenced by the extensive historical ocean voyages and expeditions which have led to a massive advancement in the scientific and geodetic knowledge about planet Earth. These global explorations via the oceans have also had strategic, economic, cultural and religious implications and impacts, which have drastically changed the state of humanity and its condition. The transportation network created by ships traveling across the oceans has been supplemented by other transportation networks on land and in the air, creating a global economy that, in general, has improved the human condition leading to better health, longer lives, lower child mortality, better education, political freedom, higher gross national product (GNP) and improved hygiene. The logical extension of this societal trend is to extend the transportation network and human civilization into outer space, beyond the cradle of planet Earth. Our solar system contains vast amounts of natural resources which can be harnessed and used to bootstrap a space economy and related infrastructure by using advanced technologies. Sailing journeys from hundreds of years ago required large vessels and large crews, (in comparison with today’s space capsules). Modern sailors of today are able to complete large voyages, in small vessels, with a minimal crew, comparable in magnitude to modern space travel. This paper will use a systems engineering approach (e.g. using the NASA Human Integration Design Handbook (HIDH), NASA-SP-2010-3407, 2010 and the “Advanced Life Support Baseline Values and Assumptions Document, (BVAD)” NASA-CR-2004-208941, 2004.), to examine and compare the logistics and sustainability aspects of a small crew traveling on Earth's oceans in sailing vessels versus humans traveling in space. The “Mālama Honua Worldwide Voyage” of the Hokule’a, a replica of an ancient Hawaiian double hulled sailing canoe, will be used as a case study. This is the best comparison case since the Polynesian exploration of the vast (and virtually empty) Pacific Ocean is the closest analogue to modern space travel. “"Both are voyages of exploration.” –Shuttle astronaut Lacy Veach. Minimizing waste and maximizing re-use and re-cycling will lead to more efficient logistics and sustainability. In addition, In-Situ Resource Utilization (ISRU) strategies, based on successful Earth based strategies used for many years by sailors will be considered and evaluated for their usefulness. For example, human logistics for a typical space mission are shown in Table 1 and Table 2 (Lopez et al, 2015). Studies show that typical human water consumption in space is projected to be 3.2 kg/day per crew member as shown in Table 2. Data from human sailing voyages around the globe will be examined. Anecdotal evidence indicates that knowledgeable and well-equipped modern sailors, who conserve water, can comfortably live using 1.5 to 5 kg/day per person. This paper will investigate key logistics and sustainability aspects of living in space and compare them quantitatively to similar aspects of living on ocean faring sailing vessels on Earth. Mutually beneficial observations, advanced technologies and modern considerations will be applied within confines of a remote sailing environment, which could be of immense value to both the space faring community and the ocean sailing community.
Space Mining for resources such as water ice, and regolith, which contain many elements in the form of metals, minerals, volatiles and other compounds, is a necessary step for In-Situ Space Resource Utilization (ISRU). One of the primary goals is to extract propellants from the regolith and water ice, such as oxygen and hydrogen which could then be used for in-space transportation. In addition, the space mining system can be used for various construction tasks that can benefit human and robotic exploration as well as scientific investigations based on excavated exposed topography, such as the side walls of trenches. The National Aeronautics & Space Ad-ministration (NASA) Lunabotics Robotic Mining Competition (RMC) is a university-level competition designed to engage and retain students in science, technology, engineering and mathematics (STEM). NASA has directly benefited from the competition by encouraging the development of innovative lunar excavation concepts from universities which has resulted in clever ideas and solutions which could be applied to an actual lunar excavation device or payload. The challenge is for students to design and build a remote controlled or autonomous excavator, called a lunabot, that can collect and deposit a minimum of 10 kilograms of lunar simulant within 15 minutes. In recent years the goal has been changed to excavate a minimum of 1 kg of simulated icy regolith which is found under an over-burden of regolith simulant. The complexities of the challenge include the abrasive characteristics of the lunar simulant, the weight and size limitations of the lunabot, and the ability to control the lunabot from a remote control center. This paper will present the results of the 10 Lunabotics Robotic Mining Competitions held between May 2010 and May 2019. Each year over 50 university teams have attended, resulting in over 500 lunabot designs and subsequent prototypes. Over 5,000 university students have been part of the competition on-site at KSC. More students and the public were en-gaged via internet broadcasting and social net-working media. The various designs will be cataloged and categorized to provide information to future Lunabotics mining robot designers and competitors. It is also expected to be of value for actual future space missions, as knowledge is gained from testing many innovative prototypes in simulated lunar regoith. A taxonomy of robotic excavator designs will be presented.
Ocean exploration sailing journeys from hundreds of years ago typically required large vessels and large crews (in comparison with today’s space capsules) to travel between the continents and around the world. Modern sailors of today are able to complete similar distant voyages, in small vessels, with a minimal crew, comparable in size to modern space travel crews. This paper uses a systems engineering approach (e.g. using the NASA Human Integration Design Handbook (HIDH), NASA-SP-2010-3407, 2010 and the “Advanced Life Support Baseline Values and Assumptions Document, (BVAD)” NASA-CR-2004-208941, 2004.), to examine and compare the logistics and sustainability aspects of a small crew traveling on Earth's oceans in sailing vessels versus humans traveling in space. The “Mālama Honua Worldwide Voyage” of the Hōkūleʻa, a replica of an ancient Hawaiian double hulled sailing canoe, will be used as a baseline minimalist case study. This is a good comparison case since the Polynesian exploration of the vast (and virtually empty) Pacific Ocean with limited resources is an analogue to human space travel. A modern sailboat is compared to the ancient Polynesian methods and then a space craft is assessed with similar functional decomposition methods. In 1992 during his second Space Shuttle mission (STS-52, Columbia) Astronaut Lacy Veach received a radio message from a student: "What are the similarities and differences between canoe and space travel?" Astronaut Charles Lacy Veach answered, "Both are voyages of exploration. Hōkūle‘a is in the past, Columbia is in the future." Navigator Nainoa Thompson added from the sailing canoe, "Columbia is the highest achievement of modern technology today, a voyaging canoe was the highest achievement of technology in its day." This paper is dedicated to the memory of two great Hawaiian astronauts: US Air Force Colonel Charles Lacy Veach and US Air Force Colonel Ellison Onizuka and to legendary waterman and Hōkūleʻa crew member Eddie Aikau who was lost at sea in 1978, at the beginning of a 30-day, 2,500-mile (4,000km) journey by the Hōkūleʻa to follow the ancient route of the Polynesian migration between the Hawaiian and Tahitian island chains.
When a lander vehicle launches or lands on the Moon, the rocket engine exhaust plume impinges on the surface and interacts with the regolith to create blast ejecta and associated cratering of the surface. Lunar regolith blast ejecta travels at high velocities (>2,000 m/s) for long distances (kilometers) in a vacuum environment [1] creating hazards for surrounding assets and it can also impact the bottom of the lander vehicle, risking damage to the engines, thermal insulation and sensors. Ballistic particles can possibly enter cislunar space and achieve orbit as debris, if the ejecta is sufficiently energetic. The cratering and regolith erosion can endanger the vehicle itself by affecting the soil stability under the landing gear. Landing on unpredictable terrain with varying topography, natural craters and rock hazards is also hazardous risks tipping a lander at dangerous angles in extreme conditions that may also violate maximum slope angles for subsequent launch operations. During launch (Figure 1), an overpressure pulse created by the ignition of the rocket engines can pose significant ejecta risks to the vehicle. Dust clouds raised during landing limit the efficacy of sensors and reduce visibility for the astronaut pilots, creating significant real-time risk during landing site selection by the pilot or computer navigation system. Future lunar spaceports will require mitigations to these launch and landing risks [2]. There are four main objectives of this effort:1) To establish the state of the art in LLP construction methodologies. 2) To propose criteria for trade studies of LLP concepts. 3) To publicly share the authors’ ideas for potential LLP solutions. 4) To serve as the starting point for future development of LLP technologies. Establishing the state of the art in the area of off-Earth Launch & Landing Pad concepts will base-line the work that has been completed thus far and highlight the wide span between current Technology Readiness Levels (TRLs)and operational readiness. The authors aim to communicate the need for funding in this area in the near term by illustrating that there is much work to be completed before a truly viable option exists. Setting forth criteria for trade studies of LLP concepts is important for several reasons. The first and most straightforward is to establish a framework for performing trade studies on LLP concepts. This will enable NASA to select the most promising concepts for continued development, and it will also help technology developers understand how their concepts compare with others and the priorities of development effort.
In situ resources offer an opportunity to reduce the amount of items brought from Earth when exploring moons and planets. Utilizing those resources requires energy that comes with a cost. In the case of human missions to Mars, trading surface power for launch mass is beneficial for propellant and consumables required to sustain human pioneering and settlement on the planet’s surface. However, In Situ Resource Utilization (ISRU) can mean far more than propellant production and consumables replacement for missions beyond Low Earth Orbit. NASA’s Systems Capability Leader-ship Team (SCLT) for ISRU created a work break-down structure based on functions identified in roadmaps pertaining to human exploration. That WBS includes Prospecting, Extraction, Processing, Construction, Manufacturing, and Energy. Over the years, NASA has developed some capabilities and technologies for prospecting, extraction, and processing carbon dioxide and water on Mars into propellants and life support consumables. However, that is a small subset of the ISRU needs that are coming to light with NASA’s push to return to the Moon for extended periods of time. For instance, astronauts require shielding from Ga-lactic Cosmic Rays and nuclear radiation and protection from the low temperatures and pressures in Space. Surface assets including crew, landers, and ascent modules can be damaged by surface ejecta during landing and launch operations on the Moon and Mars. Creating shielding, berms, and pads requires movement of large volumes and stabilization of regolith in the context of a civil engineering construction project. Because of the multi-disciplinary nature of the aerospace systems needed for human exploration, SCLT on ISRU created an ISRU Construction Integrated Steering Group that combines expertise among several NASA Principal Technologists and Capabilities Leaders for exploring options, assessing opportunities, and developing requirements for construction and manufacturing on the Moon and Mars NASA’s new program to develop Lunar landers for small, mid, and large payload deliveries to the Lunar surface leading to human missions by 2025 spawned an investigation into plume surface interactions caused by the lander during descent and ascent. The trade space to resolve this issue includes regolith stabilization via landing pad construction techniques and lander nozzles characteristics due to vehicle systems design. Some data exists from the Apollo missions but more is required for the missions ahead. The purpose of this paper [1] is to outline an approach for developing requirements that can guide systems designs while taking advantage of flight opportunities in NASA’s plans to return to the Moon.
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