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Search indexed NASA NTRS and DOE OSTI research on propulsion, heat transfer, battery materials and energy systems. Follow report and document links to the original sources.

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NASA NTRS1991

Proximity operations considerations affecting spacecraft design

Proximity operations can be defined as the maneuvering of two or more spacecraft within 1 nautical mile range, with relative velocity less than 10 feet per second. The passive vehicle is nontranslating and should provide for maintenance of the desired approach attitude. It must accommodate the active (translating) vehicle induced structural loads and performance characteristics (mating hardware tolerances), and support sensor compatibility (transponder, visual targets, etc.). The active vehicle must provide adequate sensor systems (relative state information, field-of-view, redundancy), flight control hardware (thruster sizing, minimal cross-coupling, performance margins, redundancy) and software (reconfigurable, attitude/rate modes, translation and rotation fine control authority) characteristic, and adequate non-propulsive consumables such as power. Operational concerns must be considered. These include the following: (1) the desired approach trajectory and relative orientation; (2) the active vehicle thruster plume effects (forces, torques, contamination) on the passive vehicle; and (3) procedures for contingencies such as loss of communications, sensor or propulsion failures, and target vehicle loss of control.

Staas, Steven K.↗

NASA NTRS1991

Magnetic end effectors for space operations

The Magnetic End Effector (MEE) to be flown as part of the Dexterous End Effector (DEE) flight experiment was designed to operate with the Shuttle Remote Manipulator System (SRMS). Grappling or attachment of payloads is accomplished magnetically with two fault tolerant operations. The small magnetic grapple plate weighs far less than the standard grapple fixture; allows stacking and close spacing of payloads; and eliminates secondary release mechanisms. In addition to specifics regarding the MEE, the DEE project, Magnetic Attachment Tool (MAT), RMS-Force Torque Sensor (RMS-FTS), and Targeting and Reflective Alignment Concept (TRAC) are discussed.

Monford, Leo↗

NASA NTRS1990

Flight telerobotic servicer

Viewgraphs on the Space Station Flight Telerobotic Servicer (SSFTS) are presented. Topics covered include: SSFTS design; SSFTS elements; FTS mission requirements; FTS general requirements; flight telerobotic servicer - telerobot; FTS manipulator; force-torque transducer; end effector changeout mechanism; flight telerobotic servicer - end-of-arm tooling; user interfaces; FTS data management and processing; control subsystem; FTS vision subsystem and camera positioning assembly; FTS workstation display assembly panel; mini-master hand controller; and FTS NASREM system architecture.

Haley, Dennis↗

NASA NTRS1994

Dexterous end effector flight demonstration

The Dexterous End Effector Flight Experiment is a flight demonstration of newly developed equipment and methods which make for more dexterous manipulation of robotic arms. The following concepts are to be demonstrated: The Force Torque Sensor is a six axis load cell located at the end of the RMS which displays load data to the operator on the orbiter CCTV monitor. TRAC is a target system which provides six axis positional information to the operator. It has the characteristic of having high sensitivity to attitude misalignment while being flat. AUTO-TRAC is a variation of TRAC in which a computer analyzes a target, displays translational and attitude misalignment information, and provides cues to the operator for corrective inputs. The Magnetic End Effector is a fault tolerant end effector which grapples payloads using magnetic attraction. The Carrier Latch Assembly is a fault tolerant payload carrier, which uses mechanical latches and/or magnetic attraction to hold small payloads during launch/landing and to release payloads as desired. The flight experiment goals and objectives are explained. The experiment equipment is described, and the tasks to be performed during the demonstration are discussed.

Carter, Edward L.↗

NASA NTRS1995

Simulating the dynamic interaction of a robotic arm and the Space Shuttle remote manipulator system

Industrial robots are usually attached to a rigid base. Placing the robot on a compliant base introduces dynamic coupling between the two systems. The Vehicle Emulation System (VES) is a six DOF platform that is capable of modeling this interaction. The VES employs a force-torque sensor as the interface between robot and base. A computer simulation of the VES is presented. Each of the hardware and software components is described and Simulink is used as the programming environment. The simulation performance is compared with experimental results to validate accuracy. A second simulation which models the dynamic interaction of a robot and a flexible base acts as a comparison to the simulated motion of the VES. Results are presented that compare the simulated VES motion with the motion of the VES hardware using the same admittance model. The two computer simulations are compared to determine how well the VES is expected to emulate the desired motion. Simulation results are given for robots mounted to the end effector of the Space Shuttle Remote Manipulator System (SRMS). It is shown that for fast motions of the two robots studied, the SRMS experiences disturbances on the order of centimeters. Larger disturbances are possible if different manipulators are used.

Garrahan, Steven L.↗

NASA NTRS1995

Some mechanical design aspects of the European Robotic Arm

The European Robotic Arm (ERA) is a contribution to the Russian Segment of the International Space Station Alpha. It will start operating on the Russian Segment during the assembly phase. ERA is designed and produced by a large industrial consortium spread over Europe with Fokker Space & Systems as prime contractor. In this paper, we will describe some of the overall design aspects and focus on the development of several mechanisms within ERA. The operation of ERA during the approach of its end effector towards the grapple interface and the grapple operation is discussed, with a focus on mechanisms. This includes the geometry of the end effector leading edge, which is carefully designed to provide the correct and complete tactile information to a torque-force sensor (TFS). The data from this TFS are used to steer the arm such that forces and moments are kept below 20 N and 20 N.m respectively during the grappling operation. Two hardware models of the end effector are built. The problems encountered are described as well as their solutions. The joints in the wrists and the elbow initially used a harmonic drive lubricated by MoS2. During development testing, this combination showed an insufficient lifetime in air to survive the acceptance test program. The switch-over to a system comprising planetary gearboxes with grease lubrication is described. From these development efforts, conclusions are drawn and recommendations are given for the design of complex space mechanisms.

Lambooy, Peter J.↗

NASA NTRS2004

Flywheel Technology

Throughout the summer of 2004, I am working on a number of different projects. While located in the Space Power and Propulsion Test Engineering branch, my main area of study is flywheel technology. I have been exposed to flywheels, their components, and their uses in today's society. I have been able to experience numerous flywheels here in the flywheel lab at NASA Glenn. My first main project was to explore the attributes and physical characteristics of a flywheel. Our branch was constructing a flywheel demonstration to be presented at the public open house taking place in June. Our Flywheel Interactive Demo, or FIDO, represents a real life multi-flywheel system here at NASA. I was given the opportunity to learn about how these flywheels store energy and are able to position a satellite. With all of this new knowledge, I was able to create the posters that explained how our demonstration worked. I also composed a step-by-step process made up of four experiments that any visitor could follow and perform on FIDO. By stepping through these experiments, the individual learns how a flywheel works. They not only read the explanation of what is happening, but they are also able to see it happen. Creating these two posters not only taught me, but also helped teach the general public during the open house, how flywheel technology is a very important part of our future. Through my research, I have learned that flywheels are able to store massive amounts of energy. They can be described as an electro-mechanical battery that stores kinetic energy while rotating. The faster it rotates, the more energy it stores. Their lifetime is about triple that of an ordinary battery. Flywheels also have the ability to combine energy storage with attitude control all in a single system. Attitude control is the ability to position a satellite as required. FIDO helps us to understand the rotational force (torque) that is applied upon a turn-table or satellite during wheel acceleration/deceleration. My other main project that I have just begun is to create a flywheel presentation, brochure, and video all explaining the history, applications, early attempts, and working processes of modem flywheels. These items are all usefull tools for educating school children and even adults about flywheels. This task will require a large amount of research and skills in the use of multiple applications. My goal this summer is to learn the dynamics and uses of a flywheel in today s society, and then inform and encourage the public about flywheels. I am able to express my knowledge by creating some effective as well as attractive posters, presentations, brochures, videos, etc. that are able to explain how a flywheel works along with how our FIDO demonstration simulates a real flywheel. My goal is underway, and should be successfully reached with the help of my mentor, other coworkers, and fellow interns.

Ritchie, Lisa M.↗

NASA NTRS1996

A PC-Based Controller for Dextrous Arms

This paper describes the architecture and performance of a PC-based controller for 7-DOF dextrous manipulators. The computing platform is a 486-based personal computer equipped with a bus extender to access the robot Multibus controller, together with a single board computer as the graphical engine, and with a parallel I/O board to interface with a force-torque sensor mounted on the manipulator wrist.

controller PC-Based Controller Dextrous Arms 7-DOF↗

NASA NTRS2009

Calibration Laboratory Capabilities Listing as of April 2009

This document reviews the Calibration Laboratory capabilities for various NASA centers (i.e., Glenn Research Center and Plum Brook Test Facility Kennedy Space Center Marshall Space Flight Center Stennis Space Center and White Sands Test Facility.) Some of the parameters reported are: Alternating current, direct current, dimensional, mass, force, torque, pressure and vacuum, safety, and thermodynamics parameters. Some centers reported other parameters.

Kennedy, Gary W.↗

NASA NTRS2010

Estimation and Control for Autonomous Coring from a Rover Manipulator

A system consisting of a set of estimators and autonomous behaviors has been developed which allows robust coring from a low-mass rover platform, while accommodating for moderate rover slip. A redundant set of sensors, including a force-torque sensor, visual odometry, and accelerometers are used to monitor discrete critical and operational modes, as well as to estimate continuous drill parameters during the coring process. A set of critical failure modes pertinent to shallow coring from a mobile platform is defined, and autonomous behaviors associated with each critical mode are used to maintain nominal coring conditions. Autonomous shallow coring is demonstrated from a low-mass rover using a rotary-percussive coring tool mounted on a 5 degree-of-freedom (DOF) arm. A new architecture of using an arm-stabilized, rotary percussive tool with the robotic arm used to provide the drill z-axis linear feed is validated. Particular attention to hole start using this architecture is addressed. An end-to-end coring sequence is demonstrated, where the rover autonomously detects and then recovers from a series of slip events that exceeded 9 cm total displacement.

Hudson, Nicolas↗

NASA NTRS2014

Manufacturing Challenges Associated with the Use of Metal Matrix Composites in Aerospace Structures

Metal Matrix Composites (MMCs) consist of a metal alloy reinforced with ceramic particles or fibers. These materials possess a very high strength to weight ratio, good resistance to impact and wear, and a number of other properties which make them attractive for use in aerospace and defense applications. MMCs have found use in the space shuttle orbiter's structural tubing, the Hubble Space Telescope's antenna mast, control surfaces and propulsion systems for aircraft, and tank armors. The size of MMC components is severely limited by difficulties encountered in joining these materials using fusion welding. Melting of the material results in formation of an undesirable phase (formed when molten Aluminum reacts with the reinforcement) which leaves a strength depleted region along the joint line. Friction Stir Welding (FSW) is a relatively nascent solid state joining technique developed at The Welding Institute (TWI) in 1991. The process was first used at NASA to weld the super lightweight external tank for the Space Shuttle. Today FSW is used to join structural components of the Delta IV, Atlas V, and Falcon IX rockets as well as NASA's Orion Crew Exploration Vehicle and Space Launch System. A current focus of FSW research is to extend the process to new materials, such as MMCs, which are difficult to weld using conventional fusion techniques. Since Friction Stir Welding occurs below the melting point of the workpiece material, this deleterious phase is absent in FSW-ed MMC joints. FSW of MMCs is, however, plagued by rapid wear of the welding tool, a consequence of the large discrepancy in hardness between the steel tool and the reinforcement material. This chapter summarizes the challenges encountered when joining MMCs to themselves or to other materials in structures. Specific attention is paid to the influence of process variables in Friction Stir Welding on the wear process characterizes the effect of process parameters (spindle speed, traverse rate, and length of joint) on the wear process. A phenomenological model of the wear process was constructed based on the rotating plug model of Friction Stir Welding. The effectiveness of harder tool materials (such as Tungsten Carbide, high speed steel, and tools with diamond coatings) to combat abrasive wear is also explored. In-process force, torque, and vibration signals are analyzed to assess the feasibility of in situ monitoring of tool shape changes as a result of wear (an advancement which would eliminate the need for off-line evaluation of tool condition during joining). Monitoring, controlling, and reducing tool wear in FSW of MMCs is essential to implementation of these materials in structures (such as launch vehicles) where they would be of maximum benefit. The work presented here is extendable to machining of MMCs, where wear of the tool is also a limiting factor.

Prater, Tracie↗

NASA NTRS2015

Load Bearing Equipment for Bone and Muscle Project

Axial skeletal loads coupled with muscle torque forces around joints maintain bone. Astronauts working in pairs to exercise can provide high eccentric loads for each other that are most effective. A prototype of load bearing equipment that will allow astronauts to perform exercises using each other for counter force generation in a controlled fashion and provide eccentric overload is proposed. A frame and attachments that can be rapidly assembled for use and easily stored will demonstrate feasibility of a design that can be adapted for ISS testing and Orion use.

Terrier, Douglas↗

NASA NTRS2018

Proprioceptive Inference for Dual-Arm Grasping of Bulky Objects Using RoboSimian

This work demonstrates dual-arm lifting of bulky objects based on inferred object properties (center of mass (COM) location, weight, and shape) using proprioception (i.e. force torque measurements). Data-driven Bayesian models describe these quantities, which enables subsequent behaviors to depend on conﬁdence of the learned models. Experiments were conducted using the NASA Jet Propulsion Laboratory’s (JPL) RoboSimian to lift a variety of cumbersome objects ranging in mass from 7kg to 25kg. The position of a supporting second manipulator was determined using a particle set and heuristics that were derived from inferred object properties. The supporting manipulator decreased the initial manipulator’s load and distributed the wrench load more equitably across each manipulator, for each bulky object. Knowledge of the objects came from pure proprioception (i.e. without reliance on vision or other exteroceptive sensors) throughout the experiments.

Backes, Paul↗

NASA NTRS2022

Actuator and Motor Control End-to-End V&V on the Mars 2020 Rover

The Mars 2020 Perseverance rover is the most advanced robotic exploration system ever sent to another planet. To support the complex scientific and mobility needs of the mission, the rover utilizes 33 actuators, three multi-degree-of-freedom force-torque sensors, fifteen single or dual-speed resolvers, two solenoid valves, and twelve contact switches. The control for these actuators and sensors is achieved by several levels of flight software, coordinated between two computers with varying bandwidth control loops. Furthermore, the actuators and sensors were integrated into multiple larger robotic mechanisms that were delivered by different organizations at various points in the Integration and Test (I&T) timeline. All of this created a very complex Verification and Validation (V&V) scenario involving multiple subsystems and teams, several hardware and software testbeds with varying levels of fidelity, and significant systems engineering to ensure the overall I&T schedule could be maintained while ensuring system hardware safety.This paper details the integrated V&V effort across multiple teams and venues to provide full coverage of all necessary functionality, performance, and fault protection. First, it provides an overview of how the V&V campaign was subdivided among teams and venues and provides descriptions of the various hardware configurations used to support the testing. The Mars 2020 implementation of the plan incorporates many of the lessons learned from Mars Science Laboratory’s test campaign, and these value-added modifications are discussed here. Also included in this section is the system-level environmental testing approach used for mechanisms. Second, the paper describes the phased approach used by the teams to support new hardware and software deliveries to testbed and Systems I&T. In this approach the test campaign was built upon higher-level mechanism needs for performance, functionality, and safety at specific times in the campaign. Finally, the paper discusses lessons learned from the V&V campaign that should be applied to future large-scale motion control testing efforts.

Borne, Davis↗

NASA NTRS2022

Electrical Ground Support Equipment for the Sampling Caching System of the Mars 2020 Rover

In this work we describe in detail the architecture, design, testing and operation of the Electrical Ground Support Equipment (EGSE) “Blue Box” used to test and validate the Sampling Caching System (SCS) of the Mars 2020 Perseverance rover. The Blue Box architecture is centered around COTS motor controllers and COTS input-output modules communicating over an EtherCAT bus. A custom, low-level safety subsystem ensures no harm can be done to the flight articles. The modular architecture of the EGSE reduces cost and complexity while expediting assembly time. The Blue Box drives the 19 actuators of the SCS which span the main robotic arm, the corer system, the internal sample handling arm, the sample tube sealing system and the gas dust removal tool; mimicking the Rover Motor Control Assembly (RMCA). Due to the limited availability of RMCA’s, the EGSE enabled and performed the bulk of testing activities for SCS. The majority of the SCS actuators are composed of a 3-phase DC brushless motors, hall sensors for commutation, dual resolvers for output angular measurement, brakes, heaters and platinum thermistors. Additionally, the EGSE read 12 strain gauges forming part of a force torque sensor, and switches used for external positioning references. Over the 3-year span of the V&V campaign for the SCS, over 32 EGSE systems were built, tested and deployed to test venues at JPL and externally. The EGSE tested several families of the SCS subsystem, ranging from engineering units, life test units and two flight units. Test venues that this EGSE supported included lab benches, ultra-clean cleanrooms, ATLO facilities, and thermal vacuum chambers. Together with the test software systems, SSDEV and SSDEV-ECAT, the Blue Box EGSE enabled the team to efficiently test flight hardware and flight software together. We go over the safety features and fault management techniques employed to protect flight hardware. The effects of the long, 50-feet, EGSE harnesses on motor performance, EMI, electrical noise, and motor control performance are explained. Mitigations to these unwanted effects, including shielding strategy and inductance compensation, are summarized. We go over an excerpt of notable anomalies that this EGSE suffered through its operation, along with investigations and resolutions. Lessons learned, areas of improvement as part of future work, and recommendations for future implementations for similar EGSE’s, are shared.

Levine, Dan↗

NASA NTRS2022

Mid-Air Helicopter Delivery at Mars Using a Jetpack

Mid-Air Helicopter Delivery (MAHD) is a new Entry, Descent and Landing (EDL) architecture to enable in situ mobility for Mars science at lower cost than previous rover missions. It uses a jetpack to slow down a Mars Science Helicopter (MSH) after separation from the backshell, and reach aerodynamic conditions suitable for helicopter take-off in mid air. MAHD's lander-free approach leaves enough room in the aeroshell to accommodate larger rotors. This drastically improves flight performance compared to heritage EDL approaches, notably +60\% science payload mass. MAHD also brings cost savings, a simpler architecture, improved surface access and can reach higher elevations on Mars. This paper introduces a design for the MAHD system architecture and operations. We present a mechanical configuration which fits both MSH and the jetpack within the 2.65-m Mars heritage aeroshell, and a jetpack control architecture which fully leverages the available helicopter avionics. We discuss preliminary numerical models of the flow dynamics resulting from the interaction between the jets, the rotors and the side winds. We define a force-torque sensing architecture capable of handling the wind and trimming the rotors to prepare for safe take-off. Finally, we analyze the dynamic environment and closed-loop control simulation results to demonstrate the preliminary feasibility of MAHD.

Balaram, J.↗

NASA NTRS1974

Robot arm dynamics and control

Variations in total inertia and gravity loads at the joint outputs are treated along with the relative importance of gravity and acceleration-generated reaction torques or forces versus inertia torques or forces. The relation between the dynamical state equations in explicit terms and servoing the manipulator is briefly discussed in the framework of state variable feedback control which also forms the basis of adaptive manipulator control. Exact state equations were determined for total inertia and gravity loads at the joint outputs as a function of joint variables, using the constant inertial and geometric parameters of the individual links defined in the respective link coordinate frames. The range of maximum variations in total inertia and gravity loads at the joint outputs was calculated for both no load and load in the hand. The main result is the construction of a set of greatly simplified state equations which describe the total inertia and gravity load variations at the output of the six joints with an average error of less than 5%.

Bejczy, A. K.↗

NASA NTRS1980

Kinesthetic coupling between operator and remote manipulator

A universal force-reflecting hand controller has been developed which allows the establishment of a kinesthetic coupling between the operator and a remote manipulator. The six-degree-of-freedom controller was designed to generate forces and torques on its three positional and three rotational axes in order to permit the operator to accurately feel the forces encountered by the manipulator and be as transparent to operate as possible. The universal controller has been used in an application involving a six-degree-of-freedom mechanical arm equipped with a six-dimensional force-torque sensor at its base. In this application, the hand controller acts as a position control input device to the arm, while forces and torques sensed at the base of the mechanical hand back drive the hand controller. The positional control relation and the back driving of the controller according to inputs experienced by the force-torque sensor are established through complex mathematical transformations performed by a minicomputer. The hand controller is intended as a development tool for investigating force-reflecting master-slave manipulator control technology.

Bejczy, A. K.↗