In-space Servicing, Assembly and Manufacturing (ISAM)
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Justin R Jackson↗
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Roadside Assistance on Our Journey Through Space: In-space Servicing, Assembly, and Manufacturing (ISAM) at NASA
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Robotics↗
In-space Servicing, Assembly, and Manufacturing (ISAM) State of Play- 2023 Edition
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Dale Arney↗
Design and Applications of Tethered Spacecraft Simulators
Small, tethered spacecraft, or space tugs, are a promising space capability. They can be deployed on tethers and used for a wide variety of in-space activities; a large portion of which fall under in-space servicing, assembly, manufacturing (ISAM) functions. This includes functions such as structural mating and assembly, servicing, proximity operations, capture, docking, mating, and relocation. However, there is a great deal of work to be done to raise the Technology Readiness Level (TRL) of the capabilities needed to fully realize these capabilities. The Flat Floor Robotics Lab (FFRL) at NASA’s Marshall Spaceflight Center (MSFC) has been working on space tug development for several years. The eponymous floor is 44 by 86 feet, made from a self-leveling epoxy. This creates an extremely smooth surface that air bearings can float on with very little friction, creating a simulation of zero gravity in a two-dimensional plane. The lab has several platforms of various sizes that act as vehicle simulators for testing sensors, control algorithms, mechanisms, etc. One of these platforms is a small spacecraft simulator, which can be tethered to simulate a space tug. In the last several months, the FFRL team has been working with MSFC’s welding group to conduct a laser beam welding demonstration on air bearing platforms. This demo is utilizing a space tug simulator to fly up to a floating weld platform, where two parts are clamped together and laser welded. The space tug simulator has an air bearing to provide float, as well as several actuated air thrusters to provide propulsion and make the simulator maneuverable. Currently, flights of this simulator are completed by a human operator. An RF hand controller sends signals to both actuate and fire three sets of thrusters on the simulator. This makes any maneuvers of the space tug highly subject to human error, and operators must have dedicated practice time before being able to perform maneuvers with any sufficient reliability. For the current laser welding demonstration, human operated performance is sufficient, but future implementations of in-space welding and other ISAM efforts will require higher precision, reliability, and autonomy. MSFC has funded a project that will allow a small team in the FFRL to develop the next generation of space tug simulator, which will be automated. Closed loop control will allow a user to command a position, or set of positions, that the simulator will be able to “fly” to on its own. This Maneuverable Automated Tethered Spacecraft (MATS) simulator will have configurable design, to allow a variety of payloads and mission configurations to be demonstrated on the air bearing floor. This will be an invaluable test bed for low and mid TRL advancement for space tether mission subsystems, such as more advanced demonstrations of in-space welding. Once one MATSS is constructed and demonstrated effectively, several more can be built, enabling more advanced tether missions; Electric Sail test beds, sensor arrays, and other science-enabling missions. This paper will detail the design and test of the FFRL’s MATS simulator, including efforts to establish closed loop control and autonomous capabilities. It will also detail use cases for this technology, and how it will further develop both develop science and exploration missions.
Space Tethers↗
Teleoperation and Visualization Interfaces for Remote Intervention in Space
Approaches to robotic manufacturing, assembly, and servicing of in-space assets range from autonomous operation to direct teleoperation, with many forms of semi-autonomous teleoperation in between. Because most approaches require one or more human operators at some level, it is important to explore the control and visualization interfaces available to those operators, taking into account the challenges due to significant telemetry time delay. We consider one motivating application of remote teleoperation, which is ground-based control of a robot on-orbit for satellite servicing. This paper presents a model-based architecture that: 1) improves visualization and situation awareness, 2) enables more effective human/robot interaction and control, and 3) detects task failures based on anomalous sensor feedback. We illustrate elements of the architecture by drawing on 10 years of our research in this area. The paper further reports the results of several multi-user experiments to evaluate the model-based architecture, on ground-based test platforms, for satellite servicing tasks subject to round-trip communication latencies of several seconds. The most significant performance gains were obtained by enhancing the operators’ situation awareness via improved visualization and by enabling them to precisely specify intended motion. In contrast, changes to the control interface, including model-mediated control or an immersive 3D environment, often reduced the reported task load but did not significantly improve task performance. Considering the challenges of fully autonomous intervention, we expect that some form of teleoperation will continue to be necessary for robotic in-situ servicing, assembly, and manufacturing tasks for the foreseeable future. We propose that effective teleoperation can be enabled by modeling the remote environment, providing operators with a fused view of the real environment and virtual model, and incorporating interfaces and control strategies that enable interactive planning, precise operation, and prompt detection of errors.
space robotics↗
The Space Superhighway: Enabling Active Debris Remediation Through an In-Space Logistics Infrastructure
The Space Superhighway is a future space infrastructure concept intended to support civil, commercial, and national security space interests by providing In-Space Servicing, Assembly, and Manufacturing (ISAM) services across low Earth orbit (LEO), geosynchronous orbit (GEO), and cislunar space. This concept was originally developed by an interagency working group and commissioned by the Executive Office of the President. The Space Superhighway is comprised of three primary components: regional hubs, a sustainable transportation network, and Earth-to-orbit logistics. This study establishes methods which may be used to quantify the cost-savings from use of the Space Superhighway infrastructure and interrogates the effects of the use of this logistics network on a specific use case – removal of 26 pieces of large space debris within LEO. Through application of the established methods and assuming an emplaced Space Superhighway infrastructure with no cost implications related to deployment of infrastructure-related spacecraft, this study found that the cost to use an established Space Superhighway infrastructure to remove the targeted debris may be cheaper than removal of the targeted debris through traditional methods when the ΔV between a regional hub hosting propellant and the debris field is less than 1500 m/s. Through determining optimized locations of regional hubs within LEO, this study estimates that such a ΔV is within expectations for a LEO environment supported by a fully evolved Space Superhighway logistics infrastructure. This study provides a blueprint for future Space Superhighway value proposition studies for other use cases which, when combined, may provide the ultimate benefit and justification for the proliferation of an interconnected Space Superhighway.
Space Superhighway↗
The Space Superhighway: Enabling Active Debris Remediation Through an In-Space Logistics Infrastructure
The Space Superhighway is a future space infrastructure concept intended to support civil, commercial, and national security space interests by providing In-Space Servicing, Assembly, and Manufacturing (ISAM) services across low Earth orbit (LEO), geosynchronous orbit (GEO), and cislunar space. This concept was originally developed by an interagency working group and commissioned by the Executive Office of the President. The Space Superhighway is comprised of three primary components: regional hubs, a sustainable transportation network, and Earth-to-orbit logistics. This study establishes methods which may be used to quantify the cost-savings from use of the Space Superhighway infrastructure and interrogates the effects of the use of this logistics network on a specific use case – removal of 26 pieces of large space debris within LEO. Through application of the established methods and assuming an emplaced Space Superhighway infrastructure with no cost implications related to deployment of infrastructure-related spacecraft, this study found that the cost to use an established Space Superhighway infrastructure to remove the targeted debris may be cheaper than removal of the targeted debris through traditional methods when the ΔV between a regional hub hosting propellant and the debris field is less than 1500 m/s. Through determining optimized locations of regional hubs within LEO, this study estimates that such a ΔV is within expectations for a LEO environment supported by a fully evolved Space Superhighway logistics infrastructure. This study provides a blueprint for future Space Superhighway value proposition studies for other use cases which, when combined, may provide the ultimate benefit and justification for the proliferation of an interconnected Space Superhighway.
Space Superhighway↗
Advanced Materials and Feedstock Development for On-orbit Manufacturing
This presentation is for the On-orbit Servicing, Assembly, and Manufacturing (OSAM) Technology Transfer Workshop. The content discusses materials research done to date, and research that is ongoing, applicable to OSAM applications. The talk includes content from the In-Space Manufacturing and Moon to Mars Planetary Autonomous Construction Technology projects.
On-orbit Servicing Assembly and Manufacturing↗
NASA’s Exploration and In-Space Services (NExIS) Division OSAM-1 and Related Propellant Transfer Subsystem Progress through FY 2024 Presentation
NASA’s Exploration and In-Space Services (NExIS) Division has been developing technologies for the on-orbit servicing of satellites for decades (Hubble servicing missions) On-Orbit Servicing, Assembly and Manufacturing mission 1 (OSAM-1) had plans to robotically refuel a heritage satellite on-orbit (a.k.a. non-cooperative) Future plans of the OSAM-1 flight hardware will not be discussed The OSAM-1 Space Infrastructure Dexterious Robot (SPIDER) payload is designed to assemble a 3-meter communications antenna OSAM-1 Propellant Transfer Subsystem (PTS) development supports the nascent in-space refueling ISAM goals Reference “National In-Space Servicing, Assembly, and Manufacturing Implementation Plan” (Dec 2022 from White House Office of Science and Technology Policy) ISAM fluid transfer technology shortfalls still exist and are actively being addressed at NASA
PTS↗
Lunar Assembly and Service by Autonomous Robotics (LASAR): Towards Laser Manufacturing on the Lunar Surface
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Lunar Surface↗
Maneuverable Automated Tethered Space Tug Simulator
This TIP will develop autonomous capabilities for the space tugs in the Flat Floor Robotics Laboratory (FFRL) for use in support of In-Space Servicing, Assembly, and Manufacturing (ISAM) and future vehicles in the FFRL. The space tugs would be housed on larger spacecraft, such as ISS or Gateway, and deployed for various ISAM activities. When these activities are complete, the space tug can be reeled back to its host spacecraft.
Flat Floor Robotics Lab↗
Near-term Persistent Platform Orbital Testbed: Three Candidate Architecture Options
On-orbit Servicing, Assembly, and Manufacturing (OSAM) will revolutionize the space industry by transforming the concept of operations of space systems and enabling new, radically different system implementations. These new implementations will benefit from a novel persistent asset design paradigm which focuses on evolvable designs that are tailored to the operational environment, not the launch environment. In addition, the ability to launch sub-systems independently enable future persistent assets to economically expand in capability and size, achieving cost effective and productive operations lasting for decades like terrestrial observatories. With few exceptions (International Space Station, Hubble Space Telescope, Mission Extension Vehicle customers), current space systems are not visited once they are operational. Leveraging emerging low cost commercial launch provides the ability to repeatedly and routinely revisit space systems. Thus, revolutionary new approaches for space system design are possible, creating completely new opportunities for small businesses and accelerating the growth of already established space industries. To usher in the revolutionary new operational paradigm, two things are needed. First, to build confidence in the technology and new paradigm, there must be a leading example, a bellwether persistent asset, that demonstrates the reliability and maturity of the new persistent asset paradigm (where repeated visits are common). Second, in order to rapidly advance and validate OSAM capabilities, an efficient means is required to conduct tests in the space environment. A persistent platform testbed satisfies both these needs. The space environment exhibits a plethora of characteristics that are difficult and costly to accurately simulate for a full system in a terrestrial laboratory, such as near zero gravity, a wide range of ionizing radiation types, atomic oxygen, and micro-meteoroids and space debris traveling at high velocity. In addition, since persistent assets range in mass from a few grams to several metric tons, it is difficult to accurately simulate interactions between these systems and visiting vehicles (that also exhibit a wide range of varying masses and capabilities). These interactions include the transmission of forces and/or exchanging mass (in the form of instruments, fuel, robotic assets, etc.). Thus, a rapid, versatile and cost efficient in-space testing capability that includes a persistent test platform and a surrounding in-space test zone is needed to mature technologies through experimentation. The testbed can provide common services, such as: power, thermal control, vibration isolation, data transmission between experiments and terrestrial experimenters, station-keeping, pointing, and robotic agents that can be leveraged by customer experiments. The onboard robotic agents can be used to provide payload handling services, such as: assembly, change out or upgrade, relocation, connecting/disconnecting utilities, inspection, repair or servicing, etc. Since the persistent platform cost will be amortized over many hosted payloads, its services can eventually be offered at a price much lower than if one were to design a unique and dedicated spacecraft and mission for those few experiments. The key to achieving an effective testbed is providing efficient cost effective access and infrastructure to a variety of commercial, academic and government customers coupled with extensibility, in the capability of an individual persistent platform test bed or replication of the test bed in a different operational regime. Three potential options for implementing a test bed were developed and evaluated in this study.
Persistent Platform↗
Near-term Persistent Platform Orbital Testbed: Three Candidate Architecture Options
On-orbit Servicing, Assembly, and Manufacturing (OSAM) will revolutionize the space industry by transforming the concept of operations of space systems and enabling new, radically different system implementations. These new implementations will benefit from a novel persistent asset design paradigm which focuses on evolvable designs that are tailored to the operational environment, not the launch environment. In addition, the ability to launch sub-systems independently enable future persistent assets to economically expand in capability and size, achieving cost effective and productive operations lasting for decades like terrestrial observatories. With few exceptions (International Space Station, Hubble Space Telescope, Mission Extension Vehicle customers), current space systems are not visited once they are operational. Leveraging emerging low cost commercial launch provides the ability to repeatedly and routinely revisit space systems. Thus, revolutionary new approaches for space system design are possible, creating completely new opportunities for small businesses and accelerating the growth of already established space industries. To usher in the revolutionary new operational paradigm, two things are needed. First, to build confidence in the technology and new paradigm, there must be a leading example, a bellwether persistent asset, that demonstrates the reliability and maturity of the new persistent asset paradigm (where repeated visits are common). Second, in order to rapidly advance and validate OSAM capabilities, an efficient means is required to conduct tests in the space environment. A persistent platform testbed satisfies both these needs. The space environment exhibits a plethora of characteristics that are difficult and costly to accurately simulate for a full system in a terrestrial laboratory, such as near zero gravity, a wide range of ionizing radiation types, atomic oxygen, and micro-meteoroids and space debris traveling at high velocity. In addition, since persistent assets range in mass from a few grams to several metric tons, it is difficult to accurately simulate interactions between these systems and visiting vehicles (that also exhibit a wide range of varying masses and capabilities). These interactions include the transmission of forces and/or exchanging mass (in the form of instruments, fuel, robotic assets, etc.). Thus, a rapid, versatile and cost efficient in-space testing capability that includes a persistent test platform and a surrounding in-space test zone is needed to mature technologies through experimentation. The testbed can provide common services, such as: power, thermal control, vibration isolation, data transmission between experiments and terrestrial experimenters, station-keeping, pointing, and robotic agents that can be leveraged by customer experiments. The onboard robotic agents can be used to provide payload handling services, such as: assembly, change out or upgrade, relocation, connecting/disconnecting utilities, inspection, repair or servicing, etc. Since the persistent platform cost will be amortized over many hosted payloads, its services can eventually be offered at a price much lower than if one were to design a unique and dedicated spacecraft and mission for those few experiments. The key to achieving an effective testbed is providing efficient cost effective access and infrastructure to a variety of commercial, academic and government customers coupled with extensibility, in the capability of an individual persistent platform test bed or replication of the test bed in a different operational regime. Three potential options for implementing a test bed were developed and evaluated in this study.
Persistent Platform↗
OSAM-2: Plans and Progress for the First Demonstration of Structural Manufacturing in Space
OSAM-2 began as a NASA Space Technology Mission Directorate Tipping Point project in 2016 in which an investment made in ground development and demonstration and/or flight demonstration will result in: Significant advancement of technology’s maturation High likelihood for utilization of technology in commercially fielded space application Significant improvement in ability to successfully bring space technology to market Topic area was “Robotic In-Space Manufacturing and Assembly of Spacecraft and Space Structures” Made In Space, Inc. (now Redwire) proposed Archinaut One, an in-space robotic precision manufacturing and assembly system for larger-than-deployable structures Manufacturing / assembly in the operational environment allows manufactured parts to be designed for that environment (and not for launch loads and need to deploy) In 2020 NASA budget language, NASA began using On-orbit Servicing, Assembly, and Manufacturing Mission 2 (OSAM-2) for Archinaut One Restore-L + SPIDER (SPace Infrastructure DExterous Robot) became OSAM-1 Note: Slide 7 contains video animation, best viewed in presentation mode, run time 2 mins 25 secs.
In-Space Manufacturing↗
NASA's Exploration and In-Space Services (NExIS) Division OSAM-1 Propellant Transfer Subsystem Progress 2020
National Aeronautics and Space Administration (NASA)’s Exploration and In-Space Services (NExIS) Division of Goddard Space Flight Center has been developing technology for the On-orbit Servicing, Assembly and Manufacturing Mission 1 (OSAM-1) to robotically refuel heritage and new satellites on-orbit. OSAM-1, formerly known as Restore-L, successfully passed an important NASA milestone called Key Decision Point-C (KDP-C), receiving agency-level approval for its implementation. The decision point also establishes the mission’s official schedule and budget. The OSAM-1 spacecraft, Servicing Payload and the Space Infrastructure Dexterous Robot (SPIDER) payload will refuel a satellite in space, assemble a communications antenna and manufacture a beam. By demonstrating these capabilities, the mission is advancing never-before tested technologies for use in future missions (by NASA and other government organizations and private industry). The mission is funded by the Technology Demonstration Missions program within NASA’s Space Technology Mission Directorate. This paper covers a review of servicing extensibility and critical technologies that are being developed within NExIS with a focus on the fluid transfer refueling technology within the framework of the Propellant Transfer Subsystem (PTS). An overview of the planned initial technology demonstration servicing mission via the OSAM-1 Space Vehicle is provided as an extension of the technology development progress reported in 20181, and 20192. The general objectives, challenges, and key technologies are presented as an introduction to the context of the OSAM-1 mission, and a precursor to the OSAM-1 PTS specific development status. Development and progress of the Hose Management Assembly (HMA) and Propellant Transfer Assembly (PTA) are discussed. HMA risk reduction test results including those of thermal vacuum testing are presented. Important analytical results are discussed and progress of drawings and procedures developed for the fabrication and testing phase are shown. A summary of the PTS overall verification status and design activities prepared for the critical design peer review are presented. Procurement progress is shown with status on long, medium, and short term efforts to acquire the hardware required to support the mission objectives. Technology development, challenges, and testing status are discussed with particular regard to the OSAM-1 specific key assemblies including the PTA and HMA along with the overall integrated flight mockup of the spacecraft to client fluid transfer testing conducted in the servicing testbeds. The paper concludes with key milestones leading to the goal of on-orbit refueling to be demonstrated in 2024. The overall mission Launch Readiness Date (LRD) has been realigned to accommodate budget profiles and incorporation of additional on-orbit assembly and manufacturing demonstration efforts.
Propellant transfer, satellite servicing↗
A Virtual Reality Planning Environment for High-Risk, High-Latency Teleoperation
In-Space Servicing, Assembly, and Manufacturing has the potential to enable larger-scale and longer-lived infrastructure projects in space. Servicing in particular has the potential to vastly increase the usable lifetimes of satellites, both newly launched and existing. However, some of these servicing tasks require delicate manipulation and, to apply to existing satellites, need to be able to operate on structures that were not designed for servicing and, in some cases, where the exact shape of the structure is not known in advance. For this reason, human-in-the-loop ground-based teleoperation is the only option for some missions. Ground-based teleoperation presents its own difficulties. In addition to the challenge of performing delicate operations in constrained spaces, communication with the servicing platform is subject to a variable time delay on the order of 2-7 seconds, and the only visual feedback comes from camera views with limited situational awareness and viewing angles.
Teleoperation↗
Laser Beam Welding for in-Space Joining Demonstrated Under Vacuum on the Ground and By Parabolic Flight Experiments
High energy density electron beam welding enabled the first and, to date, only American weld performed in space during the M551 experiment on Skylab in 1973. Though welding is critical to 90% of durable goods manufacturing in America, there is not yet regular and reliable application of welding processes to the In-space Servicing, Assembly, and Manufacturing (ISAM) sector. Fundamental studies are needed to develop basic capabilities and to enhance fundamental process knowledge, which will support follow-on efforts to mature in-space welding for use in commercial, defense, and other aerospace applications. The current work seeks to build on past flights and improve understanding and quantification of materials joining in space conditions using laser beam welding (LBW). LBW offers several advantages over the electron beam welding of Skylab, amongst others: reduced electromagnetic interference, less exposure of operators to ionizing radiation, and flexible delivery through optical fibers supporting unique workpieces and joints. Since there is no orbital laboratory to mature laser beam welding for space, the current effort addresses maturation of laser beam welding through parabolic flights augmented with data collection to enable numerical modeling efforts that capture the physical effects of the space environment. This team has retrofitted an LBW experimental apparatus that can simulate the vacuum and, during a parabolic flight, the reduced gravity & microgravity conditions of in-space welding. A team of Capstone students modified the setup, originally developed by NASA Langley Research Center for electron beam free-form fabrication, to replace its electron gun with a 1 kW, 1070 nm Yb fiber laser. The apparatus was further instrumented with temperature sensing and high-speed welding cameras to monitor and record changes in the thermal state of the workpiece, the melt pool, the laser penetration level, and the development and orientation of spatter & plumes. The system will operate autonomously, demonstrating its utility to uncrewed missions. During upcoming parabolic flight campaigns expected summer 2024, this LBW equipment will weld common aerospace alloys of aluminum, stainless steel, and titanium under conditions representative of the space environment. This data will guide future computational modeling efforts of laser welding in space and help to qualify in-space welding as a viable ISAM technique.
laser beam welding↗
Implementation of Field-Oriented Control in Joint Actuator Electronics for Satellite-Servicing Robotics
NASA’s OSAM-1 (On-orbit Servicing, Assembly, and Manufacturing 1) is a robotic spacecraft designed to extend the life of a satellite. Launching in 2026, the OSAM-1 servicer will use a robotic arm to grasp, refuel, and relocate Landsat 7. In order to accomplish the various servicing operations, including the critical auto-grapple capturing operation, the robot arm uses active compliance and visual servo control loops. These sophisticated control algorithms are enabled by the high performance Joint Control Boards (JCBs). At the core of the robot arm control architecture, the JCBs employ field-oriented control (FOC) to accurately commutate and efficiently control joint actuator torque. FOC offers numerous benefits over other current control methods, allowing the JCBs to achieve the high bandwidth and performance required by the outer control loops. As an added benefit, a torque feed-forward term allows the FOC loop to simulate microgravity actuator performance during ground testing. In this paper, a FOC implementation for space robotics applications and an end-to-end actuator calibration process are discussed.
Sam Zhao↗