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In-space assembly-servicing requirements

A method for developing the requirements for in-space assembly, servicing, and checkout of proposed Mars space transfer vehicles is discussed. Required in-space operations and functions are identified in relation to various Earth to Orbit (ETO) vehicles by looking at the manifesting options of baseline Mars Space Transfer Vehicles (STV). Each operation is then reduced to a minimum complexity state resulting in a set of operational primitive functions. These primitive functions are used to assess the trade-offs between robotic, telerobotic, and EVA operations. The study demonstrates that the complexity of the in-space operations remains stable with ETO vehicle size, and therefore the functions, and ultimately the infrastructure required to support proposed missions, are relatively unaffected by varying the ETO vehicle size within the range considered for this study.

Cockrell, Charles E.

Automated assembly in space

The installation of robots and their use of assembly in space will create an exciting and promising future for the U.S. Space Program. The concept of assembly in space is very complicated and error prone and it is not possible unless the various parts and modules are suitably designed for automation. Certain guidelines are developed for part designing and for an easy precision assembly. Major design problems associated with automated assembly are considered and solutions to resolve these problems are evaluated in the guidelines format. Methods for gripping and methods for part feeding are developed with regard to the absence of gravity in space. The guidelines for part orientation, adjustments, compliances and various assembly construction are discussed. Design modifications of various fasteners and fastening methods are also investigated.

Srivastava, Sandanand

In-space assembly-servicing requirements

A method for developing the requirements for in-space assembly, servicing, and checkout of the proposed Mars space transfer vehicles is discussed. Required in-space operations and functions are identified in relation to various Earth to Orbit (ETO) vehicles by looking at the manifesting options of baseline Mars Space Transfer Vehicles (STV). Each operation is then reduced to a minimum complexity state resulting in a set of operational primitive functions. These primitive functions are used to assess the tradeoffs between robotic, telerobotic, and EVA operations. The study demonstrates that the complexity of the in-space operations remains stable with ETO vehicle size, and therefore the functions, and ultimately the infrastructure required to support proposed missions, are relatively unaffected by varying the ETO vehicle size within the range considered for this study.

Cockrell, Charles E.

Structural assembly in space

A cost algorithm for predicting assembly costs for large space structures is given. Assembly scenarios are summarized which describe the erection, deployment, and fabrication tasks for five large space structures. The major activities that impact total costs for structure assembly from launch through deployment and assembly to scientific instrument installation and checkout are described. Individual cost elements such as assembly fixtures, handrails, or remote minipulators are also presented.

Stokes, J. W.

Factories-in-Space for Servicing, Assembly, & Manufacturing

Space 2.0 is a promising frontier for scientific exploration and the advancement of commerce, security, and technology. To effectively harness this potential, it is imperative to establish a multifunctional, resilient, and sustainable infrastructure that enables the maintenance and production of space-based systems. This capability is a driver for mission success on-orbit and for interplanetary travel to other celestial bodies. Central to this infrastructure is the establishment of orbital manufacturing facilities, referred to as 'factories-in-space' (FiS), which serve as critical nodes in the supply chain for the servicing, assembly, and production of systems essential for space-based operations. This paper presents a framework for understanding the key principles and design considerations underpinning FiS.

Technology

Designing a Software Architecture for the Precision Assembly of Space Structures

As NASA’s space exploration and science missions expand in complexity, longevity, anddistance beyond earth’s orbit, Orbital Servicing, Assembly and Manufacturing (OSAM)technologies and concepts have become a critical area of ongoing research and innovation.Artemis’ Moon-to-Mars goals of building sustainable elements on and around the Moon andMars that allow our robots and astronauts to explore and conduct more scientific researchwill demand in situ resource utilization, construction, and maintenance to succeed. In-spaceAssembly (ISA), as a sub-component of OSAM, focuses on the on-orbit building or fabricationof mission infrastructure and payloads. One such ISA application is highlighted by the recentNASA In-Space Assembled Telescope (iSAT) study, which stated that the next generation ofspace observatories will exceed the fairing size of existing or even planned launch vehicles andISA has emerged as a viable approach for observatory assembly. Research efforts at NASALangley Research Center have led to the design of a novel TriTruss structural concept for themodular construction of large complex persistent platforms. The TriTruss design and otherdeveloping OSAM technologies enable larger and persistent space missions that would notbe possible with single-launch-sized structures. For example, 20 meter or larger telescopesor orbital platform applications. However, the increased complexity will require autonomousoperations for the construction and maintenance of long-term infrastructure to achieve missionsuccess. NASA’s Precision Assembly of Space Structures (PASS) project is focused on thestructural and autonomy capabilities required to construct an iSAT in deep space. PASSresearch efforts will develop and validate critical technologies needed for effective efficienton-orbit assembly that can be confidently adopted for future systems. PASS will utilize theTriTruss modules to demonstrate the autonomous modular assembly of a 20m-class iSAT mirrorbackbone structure including simulated mirrors and wiring harness. In this paper, we addressthe software and hardware design considerations, technologies, and challenges of designing arobust robotics framework for assembling modular space structures in support of In SpaceAssembly missions in general as well as for PASS specifically.

Benjamin N Kelley

Guidelines and rules for automated assembly by robots in space

The development of an expert system for a 'Mechanical Design System' is discussed. Two different implementation approaches are described. One is coded in C, and the other is realized by a software package - 'Exsys.' The first method has the advantage of greater flexibility and quicker responses, while the latter one is easier to develop. This report discusses the feasible ways to establish a real mechanical intelligent design system applying artificial intelligence techniques so that the products designed by this system could best meet the requirements for space assembly.

Srivastava, Sadanand

A hierarchical planner for space truss assembly

A hierarchical planning paradigm for space truss assemblies is proposed which generates sequences of assembly operations and is suitable for human, teleoperator, and autonomous robotic implementation. Subgoals satisfying geometric (accessibility) and structural (rigidity) constraints are developed using a hierarchical state representation, and special cost functions are used to conduct a search for locally optimal sequences. Results of two case studies involving assemblies with up to 31 nodes and 102 struts are presented.

Mathur, Rajive K.

Performance analysis of a robotic system for space-based assembly

A dual arm system for space-based assembly has been under development and experimentation at the Center of Intelligent Robotic Systems for Space Exploration. This paper will describe the components of this system and will then focus on the specific problem of predicting response time of the integrated system. This hierarchical system consists of a task representation and planning level, a coordination level, and an execution level to carry out the desired assembly task. A common modeling methodology based on Petri nets was used to model the various subtasks throughout the levels of the hierarchy. The Petri net model can then be analyzed for liveness and boundedness that, in turn, are used to detect the existence of deadlock or conflict in the system. The model can also be used to calculate the time it will take to complete an assembly task once an operator issues a command. These modeling results are compared with the actual experimental results obtained from carrying out the assembly task.

Desrochers, Alan

Development and verification testing of automation and robotics for assembly of space structures

A program was initiated within the past several years to develop operational procedures for automated assembly of truss structures suitable for large-aperture antennas. The assembly operations require the use of a robotic manipulator and are based on the principle of supervised autonomy to minimize crew resources. A hardware testbed was established to support development and evaluation testing. A brute-force automation approach was used to develop the baseline assembly hardware and software techniques. As the system matured and an operation was proven, upgrades were incorprated and assessed against the baseline test results. This paper summarizes the developmental phases of the program, the results of several assembly tests, the current status, and a series of proposed developments for additional hardware and software control capability. No problems that would preclude automated in-space assembly of truss structures have been encountered. The current system was developed at a breadboard level and continued development at an enhanced level is warranted.

Rhodes, Marvin D.

On the use of maximum likelihood estimation for the assembly of Space Station Freedom

Distributed parameter models of the Solar Array Flight Experiment, the Mini-MAST truss, and Space Station Freedom assembly are discussed. The distributed parameter approach takes advantage of (1) the relatively small number of model parameters associated with partial differential equation models of structural dynamics, (2) maximum-likelihood estimation using both prelaunch and on-orbit test data, (3) the inclusion of control system dynamics in the same equations, and (4) the incremental growth of the structural configurations. Maximum-likelihood parameter estimates for distributed parameter models were based on static compliance test results and frequency response measurements. Because the Space Station Freedom does not yet exist, the NASA Mini-MAST truss was used to test the procedure of modeling and parameter estimation. The resulting distributed parameter model of the Mini-MAST truss successfully demonstrated the approach taken. The computer program PDEMOD enables any configuration that can be represented by a network of flexible beam elements and rigid bodies to be remodeled.

Taylor, Lawrence W., Jr.

In-Space Structural Assembly: Applications and Technology

As NASA exploration moves beyond earth's orbit, the need exists for long duration space systems that are resilient to events that compromise safety and performance. Fortunately, technology advances in autonomy, robotic manipulators, and modular plug-and-play architectures over the past two decades have made in-space vehicle assembly and servicing possible at acceptable cost and risk. This study evaluates future space systems needed to support scientific observatories and human/robotic Mars exploration to assess key structural design considerations. The impact of in-space assembly is discussed to identify gaps in structural technology and opportunities for new vehicle designs to support NASA's future long duration missions.

Belvin, W. Keith

Verification Test of Automated Robotic Assembly of Space Truss Structures

A multidisciplinary program has been conducted at the Langley Research Center to develop operational procedures for supervised autonomous assembly of truss structures suitable for large-aperture antennas. The hardware and operations required to assemble a 102-member tetrahedral truss and attach 12 hexagonal panels were developed and evaluated. A brute-force automation approach was used to develop baseline assembly hardware and software techniques. However, as the system matured and operations were proven, upgrades were incorporated and assessed against the baseline test results. These upgrades included the use of distributed microprocessors to control dedicated end-effector operations, machine vision guidance for strut installation, and the use of an expert system-based executive-control program. This paper summarizes the developmental phases of the program, the results of several assembly tests, and a series of proposed enhancements. No problems that would preclude automated in-space assembly or truss structures have been encountered. The test system was developed at a breadboard level and continued development at an enhanced level is warranted.

Rhodes, Marvin D.

Telerobotic research for in-space structural assembly and servicing

The paper reviews Langley's Telerobotic Technology Program and the recent and planned research in automated space assembly. Research areas include multiple manipulator coordination and control, automatic modes, evaluation of control modalities for teleoperated tasks, active sensing for world modeling and control, and architectures for distributed telerobotic systems. Studies of master/slave teleoperators performing representative space tasks showed that current teleoperator systems can be used to accomplish remote space operations. These studies also identified that research is required to improve the systems to reduce operator workload and task completion time. Closed-loop noncontact and contact sensor based control for automatic acquisition, positioning, and active compliance have been developed. A control structure for multiple manipulator coordination and control with manual, shared, and automatic modes performing space type tasks is being evaluated.

Meintel, Alfred J., Jr.