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NASA NTRS2005

Magnetically Attached Multifunction Maintenance Rover

A versatile mobile telerobot, denoted the magnetically attached multifunction maintenance rover (MAGMER), has been proposed for use in the inspection and maintenance of the surfaces of ships, tanks containing petrochemicals, and other large ferromagnetic structures. As its name suggests, this robot would utilize magnetic attraction to adhere to a structure. As it moved along the surface of the structure, the MAGMER would perform tasks that could include close-up visual inspection by use of video cameras, various sensors, and/or removal of paint by water-jet blasting, laser heating, or induction heating. The water-jet nozzles would be mounted coaxially within compressed-air-powered venturi nozzles that would collect the paint debris dislodged by the jets. The MAGMER would be deployed, powered, and controlled from a truck, to which it would be connected by hoses for water, compressed air, and collection of debris and by cables for electric power and communication (see Figure 1). The operation of the MAGMER on a typical large structure would necessitate the use of long cables and hoses, which can be heavy. To reduce the load of the hoses and cables on the MAGMER and thereby ensure its ability to adhere to vertical and overhanging surfaces, the hoses and cables would be paid out through telescopic booms that would be parts of a MAGMER support system. The MAGMER would move by use of four motorized, steerable wheels, each of which would be mounted in an assembly that would include permanent magnets and four pole pieces (see Figure 2). The wheels would protrude from between the pole pieces by only about 3 mm, so that the gap between the pole pieces and the ferromagnetic surface would be just large enough to permit motion along the surface but not so large as to reduce the magnetic attraction excessively. In addition to the wheel assemblies, the MAGMER would include magnetic adherence enhancement fixtures, which would comprise arrays of permanent magnets and pole pieces that could be adjusted to maximize or minimize the overall attractive magnetic force. Even with a paint thickness of 2 mm, a preliminary design provides a safety factor of 5 in the magnetic force in the upside- down, water-jets-operating condition, in which the total load (including the weight of the MAGMER and cables and the water-jet force) would be about 260 lb (the weight of 118 kg). Optionally, the MAGMER could carry magnetic shielding and/or could be equipped with a demagnetizing module to remove residual magnetism from the structure. The MAGMER would carry four charge-coupled-device cameras for visual inspection, monitoring of operation, navigation, and avoidance of collisions with obstacles. The control system of the MAGMER would include navigation and collision-avoidance subsystems that would utilize surface features as landmarks, in addition to direct images of obstacles.

Bar-Cohen, Yoseph↗

NASA NTRS2008

The Application of the Human Engineering Modeling and Performance Laboratory for Space Vehicle Ground Processing Tasks at Kennedy Space Center

The introduction of United Space Alliance's Human Engineering Modeling and Performance Laboratory began in early 2007 in an attempt to address the problematic workspace design issues that the Space Shuttle has imposed on technicians performing maintenance and inspection operations. The Space Shuttle was not expected to require the extensive maintenance it undergoes between flights. As a result, extensive, costly resources have been expended on workarounds and modifications to accommodate ground processing personnel. Consideration of basic human factors principles for design of maintenance is essential during the design phase of future space vehicles, facilities, and equipment. Simulation will be needed to test and validate designs before implementation.

Woodbury, Sarah K.↗

NASA NTRSDate not supplied

3D Localization of Defects in Facility Inspection

Wind tunnels are crucial facilities that support the aerospace industry. However, these facilities are large, complex, and pose unique maintenance and inspection requirements. Manual inspections to identify defects such as cracks, missing fasteners, leaks, and foreign objects are important but labor and schedule intensive. Our goal is to utilize small Unmanned Aircraft Systems (sUAS) and computer vision-based analysis to automate the inspection of the interior and exterior of NASA’s critical wind tunnel facilities. We detect missing fasteners as our defect class, and detect existing fasteners to provide potential future missing fastener sites for preventative maintenance. These detections are done on both 2D raw images and in 3D space to provide a visual reference and real world location to facilitate repairs. A dataset was created consisting of images taken along a grid-like pattern of an interior tunnel section in the AEDC National Full-Scale Aerodynamics Complex (NFAC) at NASA Ames Research Center. Our method uses object detection to create image level bounding boxes of the fasteners and missing fasteners, then uses photogrammetry to create a mapping from 2D image locations to 3D real world locations. The image level bounding boxes and the 2D to 3D mapping are then combined to determine the 3D location of the defects. We describe the data collection, photogrammetry, and computer vision techniques used for object detection as well as a quantitative analysis of the method.

Small Unmanned Aircraft Systems (sUAS)↗

DOE OSTI2021

Post-Closure Report for Closed Resource Conservation and Recovery Act Corrective Action Units, Nevada National Security Site, Nevada: For Calendar Year 2020 (Rev. 2)

This report serves as the combined annual report for post-closure activities in compliance with the requirements listed in Resource Conservation and Recovery Act (RCRA) Permit Number NEV HW0101 associated with the following closed corrective action units (CAUs): 1) CAU 90, Area 2 Bitcutter Containment; 2) CAU 91, Area 3 U-3fi Injection Well; 3) CAU 92, Area 6 Decon Pond Facility; 4) CAU 110, Area 3 WMD U-3ax/bl Crater; 5) CAU 111, Area 5 WMD Retired Mixed Waste Pits; 6) CAU 112, Area 23 Hazardous Waste Trenches The locations of the sites are shown in Figure ES-1. This report covers calendar year 2020. The post-closure requirements for these sites are described in RCRA Permit NEV HW0101 and are summarized in each CAU-specific section of this report. The results of the inspections, a summary of maintenance activities, and an evaluation of monitoring data are presented in this report. Site inspections are conducted annually at CAUs 90, 91, and 112; semiannually at CAUs 92 and 110; and quarterly at CAU 111. Additional inspections are conducted at CAUs 92 and 111 if precipitation occurs in excess of 1.0 inch in a 24-hour period. Inspections include an evaluation of the condition of the units, including covers, fences, signs, gates, and locks. At CAUs 110 and 111, soil moisture monitoring and subsidence surveys are conducted in addition to the visual inspections. At CAU 110, the site fence, gate, lock, and use restriction signs are evaluated. At CAU 111, an ecological survey, direct radiation monitoring, air monitoring, radon flux monitoring, and groundwater monitoring are also conducted. This report will address all monitoring item notes above except groundwater monitoring. Groundwater monitoring is documented in the Nevada National Security Site Data Report: Groundwater Monitoring Program Area 5 Radioactive Waste Management Site. All required inspections, maintenance, and monitoring were conducted in accordance with the post-closure requirements of the permit. Revision 6 of RCRA Permit NEV HW0101 was issued effective December 10, 2015, and remained in effect until December 10, 2020. At the time of this report submittal, the new RCRA permit application was in review.

54 ENVIRONMENTAL SCIENCES↗

NASA NTRS2003

A Survey of Space Robotics

In this paper we summarize a survey conducted by NASA to determine the state-of-the-art in space robotics and to predict future robotic capabilities under either nominal and intensive development effort. The space robotics assessment study examined both in-space operations including assembly, inspection, and maintenance and planetary surface operations like mobility and exploration. Applications of robotic autonomy and human-robot cooperation were considered. The study group devised a decomposition of robotic capabilities and then suggested metrics to specify the technical challenges associated with each. The conclusion of this paper identifies possible areas in which investment in space robotics could lead to significant advances of important technologies.

Space robotics survey↗

NASA NTRS2011

Dexterous Operations on ISS and Future Applications

The Mobile Servicing System (MSS) is a complex robotics system used extensively in the assembly, inspection and maintenance of the International Space Station (ISS). Its external components are comprised of the Space Station Remote Manipulator System (SSRMS), the Mobile Base System (MBS), and the Special Purpose Dexterous Manipulator (SPDM or "Dextre"). Dexterous robotic maintenance operations on the ISS are now enabled with the launch and deployment of "Dextre" in March 2008 and the recently completed commissioning to support nominal operations. These operations include allowing for maintenance of the MSS capability to be executed uniquely via robotic means. Examples are detailed inspection and the removal and replacement of On-orbit Replaceable Units (ORUs) located outside the pressurized volume of the ISS, alleviating astronauts from performing numerous risky and time-consuming extra-vehicular activities (EVAs). In light of the proposed extension of the ISS to 2020 and beyond, "Dextre" can also be seen as a resource for the support and conduct of external ISS experiments. "Dextre" can be utilized to move experiments around ISS, as test bed for more elaborate experiments outside the original design intent, and as a unique platform for external experiments. This paper summarizes the status of "Dextre", its planned use, and future potential for dexterous operations on the ISS. Lessons learned from the planning and execution of SPDM commissioning are first introduced, and significant differences between "Dextre" and SSRMS operations are discussed. The use of ground control as the predominant method for operating "Dextre" is highlighted, along with the benefits and challenges that this poses. Finally, the latest plans for dexterous operations on ISS are summarized including visiting vehicle unloading, nominal maintenance, and operations of a more experimental flavor.

Keenan, P. Andrew↗

NASA NTRS2012

Structural Health Monitoring with Fiber Bragg Grating and Piezo Arrays

Structural health monitoring (SHM) is one of the most important tools available for the maintenance, safety, and integrity of aerospace structural systems. Lightweight, electromagnetic-interference- immune, fiber-optic sensor-based SHM will play an increasing role in more secure air transportation systems. Manufacturers and maintenance personnel have pressing needs for significantly improving safety and reliability while providing for lower inspection and maintenance costs. Undetected or untreated damage may grow and lead to catastrophic structural failure. Damage can originate from the strain/stress history of the material, imperfections of domain boundaries in metals, delamination in multi-layer materials, or the impact of machine tools in the manufacturing process. Damage can likewise develop during service life from wear and tear, or under extraordinary circumstances such as with unusual forces, temperature cycling, or impact of flying objects. Monitoring and early detection are key to preventing a catastrophic failure of structures, especially when these are expected to perform near their limit conditions.

Black, Richard J.↗

DOE OSTI2026

Robotic automation of maintenance work in nuclear power plants a cross-sector survey and roadmap

Nuclear power plants face increasing cost pressures, workforce constraints (aging workforce and skilled labor shortages), and safety requirements that are accelerating interest in robotic systems for inspection and maintenance. We conducted semi-structured interviews with personnel from seven U.S. nuclear utilities and compared deployment models, operational use cases, and integration practices with those reported by participants in the oil, gas, and petrochemical sector. In nuclear plants, robotic use remains concentrated in inspection—particularly indoor unmanned aerial vehicles and submersible remotely operated vehicles—with limited application to physical maintenance tasks. Reported near-term value includes reduced radiological and industrial risk, reduced outage labor, and improved data for planning and condition assessment. Key barriers include integration and data-interoperability constraints, operator qualification requirements, cybersecurity review burden, and difficulty demonstrating reliability in plant-representative environments. Cross-sector benchmarking highlights organizational and deployment practices that may help nuclear plants scale from pilots to routine use. We propose a deployment-oriented roadmap emphasizing modular payload strategies, representative qualification pathways and testing environments, and improved data governance to support safe and economically justified expansion of robotics in operating nuclear power plants.

11 - NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

NASA NTRS2006

Space Robotics: AWIMR an Overview

This viewgraph presentation reviews the usages of Autonomous Walking Inspection and Maintenance Robots (AWIMR) in space. Some of the uses that these robots in support of space exploration can have are: inspection of a space craft, cleaning, astronaut assistance, assembly of a structure, repair of structures, and replenishment of supplies.

Wagner, Rick↗

DOE OSTI2023

Development of Event-Based Data Acquisition for Acoustic Emission Monitoring of the Structural Integrity of Wind Turbine Blades [Slides]

DOE Alignment: Reduce the cost of floating offshore wind energy in deep waters to $45/MWh by 2035 from today’s estimated $150/MWh20 by: Developing operations and maintenance strategies and increasing wind turbine reliability to reduce periods of non-operation and reduce labor at sea through remote system health monitoring, inspection, and maintenance capabilities incorporating artificial intelligence and predictive maintenance.

17 WIND ENERGY↗

NASA NTRS2011

Ground Processing Affordability for Space Vehicles

Launch vehicles and most of their payloads spend the majority of their time on the ground. The cost of ground operations is very high. So, why so often is so little attention given to ground processing during development? The current global space industry and economic environment are driving more need for efficiencies to save time and money. Affordability and sustainability are more important now than ever. We can not continue to treat space vehicles as mere science projects. More RLV's (Reusable Launch Vehicles) are being developed for the gains of reusability which are not available for ELV's (Expendable Launch Vehicles). More human-rated vehicles are being developed, with the retirement of the Space Shuttles, and for a new global space race, yet these cost more than the many unmanned vehicles of today. We can learn many lessons on affordability from RLV's. DFO (Design for Operations) considers ground operations during design, development, and manufacturing-before the first flight. This is often minimized for space vehicles, but is very important. Vehicles are designed for launch and mission operations. You will not be able to do it again if it is too slow or costly to get there. Many times, technology changes faster than space products such that what is launched includes outdated features, thus reducing competitiveness. Ground operations must be considered for the full product Lifecycle, from concept to retirement. Once manufactured, launch vehicles along with their payloads and launch systems require a long path of processing before launch. Initial assembly and testing always discover problems to address. A solid integration program is essential to minimize these impacts, as was seen in the Constellation Ares I-X test rocket. For RLV's, landing/recovery and post-flight turnaround activities are performed. Multi-use vehicles require reconfiguration. MRO (Maintenance, Repair, and Overhaul) must be well-planned--- even for the unplanned problems. Defect limits and standard repairs need to be in-place as well as easily added. Many routine inspections and maintenance can be like an aircraft overhaul. Modifications and technology upgrades should be expected. Another factor affecting ground operations efficiency is trending. It is essential for RLV's, and also useful for ELV's which fly the same or similar models again. Good data analysis of technical and processing performance will determine fixes and improvements needed for safety, design, and future processing. Collecting such data on new or low-frequency vehicles is a challenge. Lessons can be learned from the Space Shuttle, or even the Concorde aircraft. For all of the above topics, efficient business systems must be established for comprehensive program management and good throughput. Drawings, specifications, and manuals for an entire launch vehicle are often in different formats from multiple vendors, plus they have proprietary constraints. Nonetheless, the integration team must ensure that all data needed is compatible and visible to each appropriate team member. Ground processing systems for scheduling, tracking, problem resolution, etc. must be well laid-out. The balance between COTS (commercial off the shelf) and custom software is difficult. Multiple customers, vendors, launch sites, and landing sites add to the complexity of efficient IT (Information Technology) tools.

Ingalls, John↗

NASA NTRS1995

Orbital impacts and the Space Shuttle windshield

The Space Transportation System (STS) fleet has flown more than sixty missions over the fourteen years since its first flight. As a result of encounters with on-orbit particulates (space debris and micrometeoroids), 177 impact features (chips) have been found on the STS outer windows (through STS-65). Forty-five of the damages were large enough to warrant replacement of the window. NASA's orbital operations and vehicle inspection procedures have changes over the history of the shuttle program, in response to concerns about the orbital environment and the cost of maintaining the space shuttle. These programmatic issues will be discussed, including safety concerns, maintenance issues, inspection procedures and flight rule changes. Examples of orbital debris impacts to the shuttle windows will be provided. There will also be a brief discussion of the impact properties of glass and what design changes have been considered to improve the impact properties of the windows.

Edelstein, Karen S.↗

DOE OSTI2022

NARAC Meteorological Monitoring Tower Maintenance Report: Submarine Base Group Two, Sub Base New London NEWLBASE2 Tower

Comments: The roof-based tower is located on Building 17 on Naval Submarine Base New London. Tower installation date is unknown. A second GFCI outlet in-line with the standard GFCI in the logger enclosure is mounted on conduit out of the tower base pedestal. The roof surface has been replaced and is now safe to walk on. The tower was not climbed during this maintenance visit. After the maintenance visit in 2018, the tower was deemed unsafe to climb due to age, corrosion, and deterioration of the tower components. The wind, air temperature, and relative humidity sensors located on the upper part of the tower require climbing of the tower for servicing and could not be accessed for inspection and maintenance. The tower is scheduled for replacement in FY2023. Tasks to be Completed: Tower system replacement / relocation. Consider replacement or bypassing of the suspect precipitation gauge signal connector.

99 GENERAL AND MISCELLANEOUS↗

DOE OSTI2022

Post-Closure Report for Closed Resource Conservation and Recovery Act Corrective Action Units, Nevada National Security Site, Nevada (CY2021)

54 ENVIRONMENTAL SCIENCES↗

NASA NTRS1977

Reliability based fatigue design and maintenance procedures

A stochastic model has been developed to describe a probability for fatigue process by assuming a varying hazard rate. This stochastic model can be used to obtain the desired probability of a crack of certain length at a given location after a certain number of cycles or time. Quantitative estimation of the developed model was also discussed. Application of the model to develop a procedure for reliability-based cost-effective fail-safe structural design is presented. This design procedure includes the reliability improvement due to inspection and repair. Methods of obtaining optimum inspection and maintenance schemes are treated.

Hanagud, S.↗

NASA NTRS1992

Mission management aircraft operations manual

This manual prescribes the NASA mission management aircraft program and provides policies and criteria for the safe and economical operation, maintenance, and inspection of NASA mission management aircraft. The operation of NASA mission management aircraft is based on the concept that safety has the highest priority. Operations involving unwarranted risks will not be tolerated. NASA mission management aircraft will be designated by the Associate Administrator for Management Systems and Facilities. NASA mission management aircraft are public aircraft as defined by the Federal Aviation Act of 1958. Maintenance standards, as a minimum, will meet those required for retention of Federal Aviation Administration (FAA) airworthiness certification. Federal Aviation Regulation Part 91, Subparts A and B, will apply except when requirements of this manual are more restrictive.

Source record↗

DOE OSTI2024

An Operations and Maintenance Roadmap for U.S. Offshore Wind: Enabling a Cost-Effective and Sustainable U.S. Offshore Wind Energy Industry Through Innovative Operations and Maintenance

The United States is currently targeting 30GW of offshore wind to be installed by 2030, and 150GW by 2050. Even considering future turbine sizes, this represents thousands of new turbines installed in a diverse set of environments, each with their unique design, installation, and maintenance challenges. While much can be learned from European and Asian experience with offshore wind over the past two decades, it is important to understand the unique circumstances of the U.S. This document explores operations and maintenance of offshore wind energy, specific to the U.S. and attempts to lay out a roadmap for needed activities to ensure reliability of future installations. The roadmap was informed through dozens of interviews with a wide cross-section of the industry, including representatives from OEMs, owner/operators, service companies, certification agencies, service providers, and researchers. The roadmap first describes the problem by component - blades, drivetrain and nacelle, structures and foundations, and electrical systems - through a look at current practices and opportunities for improvement in the areas of Failure Mode Analysis and Mitigation; Monitoring, Sensing, and Inspection; and Maintenance Execution. Crosscutting areas of Digitalization, Robotics and Automation, Prognostics and Health Management and O&M Optimization, Experimentation and Demonstration, Standardization, and Design Optimization Considering Reliability and O&M are then discussed. Finally, the roadmap summarizes all of these topics with recommendations for short (1-3 years), medium (4-7 years), and long term (8-12 years) activities, with a description of needed public and private sector contributions.

17 WIND ENERGY↗

DOE OSTI2024

A nuclear power plant digital twin for developing robot navigation and interaction

As robot technologies are rapidly improving, an increasing number of new ideas on utilizing robots for automated operation and maintenance tasks in nuclear power plants (NPPs) are being studied. However, due to safety concerns, researchers hardly found opportunities to test their new robot solutions on physical NPPs. In that sense, an efficient and realistic simulation environment plays a vital role in the development of automation systems for an NPP. In this paper, we propose the design of a 3D digital twin system capable of simulating NPP in real-time. This system obtains the data from a full-scope NPP simulator to reproduce the operating conditions of the plant. In addition, a scenario of a team of robots performing inspection tasks like temperature and pressure measurements will highlight its usability. This system enables development of intelligent robot swarms to deploy for inspection and maintenance purposes. It will positively impact autonomous control and operations for many types of reactors by reducing uncertainty in autonomous control and providing the tools necessary for remote intervention.

Energy & Fuels↗