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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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Sequential edge-tracking algorithm employs circular scanning to point permit effective real-time tracking of coastlines and rivers from earth resources satellites. Technique eliminates expensive high-resolution cameras. System might also be adaptable for application in monitoring automated assembly lines, inspecting conveyor belts, or analyzing thermographs, or x ray images.
Methods are explored for economically generating electrical power to meet future requirements. The Low-Cost Silicon Solar Array Project (LSSA) was established to reduce the price of solar arrays by improving manufacturing technology, adapting mass production techniques, and promoting user acceptance. The new manufacturing technology includes the consideration of new silicon refinement processes, silicon sheet growth techniques, encapsulants, and automated assembly production being developed under contract by industries and universities.
The results are given of an advanced module development program with the objective of providing a low cost solar cell mechanical interconnect design. The design approach, which avoids soldering or welding operations, lends itself to automated assembly techniques thus supporting the Low-Cost Silicon Solar Array Project goals. The first group of six modules contained aluminum contact cells and the second group of six modules contained silver-titanium-palladium contact cells. Extensive component and environmental testing at the module level showed that reliable cell mechanical interconnection can be achieved when utilizing the proper electrical contact materials and pressures. A discussion is given of the module design, manufacturing procedure, test program, significant problem areas and solutions, and conclusions and recommendations as formulated and conducted by XEOS.
Microprocessor-controlled walking-beam conveyor moves cells between work stations in automated assembly line. Conveyor has arm at each work station. In unison arms pick up all solar cells and advance them one station; then beam retracks to be in position for next step. Microprocessor sets beam stroke, speed, and position.
The structural proportions of minimum-mass tetrahedral truss platforms designed for low earth and geosynchronous orbit are determined by means of computerized sizing techniques, taking into account multiple design requirements and constraints. Strut dimensions characterizing minimum mass designs are found to be significantly more slender than those used for conventional structural applications. It is also shown that the number of shuttle flights required by deployable trusses becomes excessive above certain critical stiffness values, and that an automated assembler can achieve rates of 1 min/strut, by comparison with 2-5 min/strut for two astronauts using manual labor.
Sorting system uses acoustic reasonance chamber, detects, and rejects anomalous parts on automated assembly line. System particularly suited to small nuts, bolts, pins, and assemblies which previously required expensive three dimensional television-monitoring systems to prevent misfeeds.
The results of a workshop of 50 representatives from the public and private sector which investigated the potential joint development of the key technologies and mechanisms that will enable the permanent habitation of space are presented. The workshop is an initial step to develop a joint public/private assessment of new technology requirements of future space options, to share knowledge on required technologies that may exist in the private sector, and to investigate potential joint technology development opportunities. The majority of the material was produced in 5 working groups: (1) Construction, Assembly, Automation and Robotics; (2) Prospecting, Mining, and Surface Transportation; (3) Biosystems and Life Support; (4) Materials Processing; and (5) Innovative Ventures. In addition to the results of the working groups, preliminary technology development recommendations to assist in near-term development priority decisions are presented. Finally, steps are outlined for potential new future activities and relationships among the public, private, and academic sectors.
Reliability is a serious problem in computer controlled robot systems. Although robots serve successfully in relatively simple applications such as painting and spot welding, their potential in areas such as automated assembly is hampered by programming problems. A program for assembling parts may be logically correct, execute correctly on a simulator, and even execute correctly on a robot most of the time, yet still fail unexpectedly in the face of real world uncertainties. Recovery from such errors is far more complicated than recovery from simple controller errors, since even expected errors can often manifest themselves in unexpected ways. Here, a novel approach is presented for improving robot reliability. Instead of anticipating errors, researchers use knowledge-based programming techniques so that the robot can autonomously exploit knowledge about its task and environment to detect and recover from failures. They describe preliminary experiment of a system that they designed and constructed.
Human operators freed from tedious, repetitive monitoring tasks. Computer program applies techniques of artificial intelligence to monitoring positions of many switches and valves. Uses combination of procedural and declarative programming techniques. NASA's C Language Integrated Production System (CLIPS) provides rule-processing capabilities. Host program, written in C, acquires necessary data and applies valuation algorithm to generate knowledge-based propositions. Written to assist human flight controllers in comparing actual with expected configuration of switches and valves in Space Shuttle; underlying programming concept applicable to other complicated systems as chemical-processing plants, power-plants, and automated assembly lines. Program works with present monitoring equipment and computers.
Automated assembly of truss structures in space requires vision-guided servoing for grasping a strut when its position and orientation are uncertain. This paper presents a methodology for efficient and robust vision-guided robot grasping alignment. The vision-guided grasping problem is related to vision-guided 'docking' problems. It differs from other hand-in-eye visual servoing problems, such as tracking, in that the distance from the target is a relevant servo parameter. The methodology described in this paper is hierarchy of levels in which the vision/robot interface is decreasingly 'intelligent,' and increasingly fast. Speed is achieved primarily by information reduction. This reduction exploits the use of region-of-interest windows in the image plane and feature motion prediction. These reductions invariably require stringent assumptions about the image. Therefore, at a higher level, these assumptions are verified using slower, more reliable methods. This hierarchy provides for robust error recovery in that when a lower-level routine fails, the next-higher routine will be called and so on. A working system is described which visually aligns a robot to grasp a cylindrical strut. The system uses a single camera mounted on the end effector of a robot and requires only crude calibration parameters. The grasping procedure is fast and reliable, with a multi-level error recovery system.
Automated assembly of truss structures in space requires vision-guided servoing for grasping a strut when its position and orientation are uncertain. This paper presents a methodology for efficient and robust vision-guided robot grasping alignment. The vision-guided grasping problem is related to vision-guided 'docking' problems. It differs from other hand-in-eye visual servoing problems such as tracking in that the distance from the target is a relevant servo parameter. The methodology described in this paper is a hierarchy of levels in which the vision/robot interface is decreasingly 'intelligent', and increasingly fast. Speed is achieved primarily by information reduction. This reduction exploits the use of region-of-interest windows in the image plane and feature motion prediction. These reductions invariably require stringent assumptions about the image. Therefore, at a higher level, these assumptions are verified using slower, more reliable methods. This hierarchy provides for robust error recovery in that when a lower-level routine fails, the next-higher routine will be called and so on. A working system is described which visually aligns a robot to grasp a cylindrical strut. The system uses a single camera mounted on the end effector of a robot and requires only crude calibration parameters. The grasping procedure is fast and reliable, with a multi-level error recovery system.
The design of a light weight, low cost phased array antenna is presented. Multilayer printed wiring board (PWB) technology is utilized for Radio Frequencies (RF) and DC/Logic manifold distribution. Transmit modules are soldered on one side and patch antenna elements are on the other, allowing the use of automated assembly processes. The 19 GHz antenna has two independently steerable beams, each capable of transferring data at 622 Mbps. A passive, self-contained phase change thermal management system is also presented.
Humanoids are steadily improving in appearance and functionality demonstrated in controlled environments. To address the challenges of operation in the real-world, researchers have proposed the use of brain-inspired architectures for robot control, and the use of robot learning techniques that enable the robot to acquire and tune skills and behaviours. In the first part of the paper we introduce new concepts and results in these two areas. First, we present a cerebellum-inspired model that demonstrated efficiency in the sensory-motor control of anthropomorphic arms, and in gait control of dynamic walkers. Then, we present a set of new ideas related to robot learning, emphasizing the importance of developing teaching techniques that support learning. In the second part of the paper we propose the use in robotics of the iterative and incremental development methodologies, in the context of practical task-oriented applications. These methodologies promise to rapidly reach system-level integration, and to early identify system-level weaknesses to focus on. We apply this methodology in a task targeting the automated assembly of a modular structure using HOAP-2. We confirm this approach led to rapid development of a end-to-end capability, and offered guidance on which technologies to focus on for gradual improvement of a complete functional system. It is believed that providing Grand Challenge type milestones in practical task-oriented applications accelerates development. As a meaningful target in short-mid term we propose the 'IKEA Challenge', aimed at the demonstration of autonomous assembly of various pieces of furniture, from the box, following included written/drawn instructions.
Versatile programmable materials have long been envisioned that can reconfigure themselves to adapt to changing use cases in adaptive infrastructure, space exploration, disaster response, and more. We introduce a robotic structural system as an implementation of programmable matter, with mechanical performance and scale on par with conventional high-performance materials and truss systems. Fiber reinforced composite truss-like building-blocks form strong, stiff, and lightweight lattice structures as mechanical metamaterials. Two types of mobile robots operate over the exterior surface and through the interior of the system, performing transport, placement, and reversible fastening using the intrinsic lattice periodicity for indexing and metrology. Leveraging programmable matter algorithms to achieve scalability in size and complexity, this system design enables robust collective automated assembly and reconfiguration of large structures with simple robots. We describe the system design and experimental results from a 256-unit cell assembly demonstration and lattice mechanical testing, as well as demonstration of disassembly and reconfiguration. The assembled structural lattice material exhibits ultra-light mass density (0.0103 g/cc) with high strength and stiffness for its weight (0.01117 MPa and 1.1129 MPa, respectively), a material performance realm appropriate for applications like space structures. With simple robots and structure, high mass-specific structural performance, and competitive throughput, this system demonstrates potential for self-reconfiguring autonomous metamaterials for diverse applications.
For almost 100 years, commercial aircraft have been fabricated using riveted aluminum alloy structures. Aside from refining aircraft designs for better aerodynamic efficiency, improving alloy compositions, and automating assembly steps, fuselage construction remains largely unchanged today. The intent of the lightweight metallic fuselage prototype undertaken in NASA’s Advanced Air Transport Technology project was to demonstrate innovative forming and joining processes that advance the design paradigm, i.e. achieve high-rate manufacturing and reduce assembly time/costs. Over the past decade, researchers at NASA Langley Research Center have evaluated the potential to modify the flow forming process to produce near-net shaped cylinders, integrally stiffened along the cylinder axis, for space launch vehicles. The production of integral stiffeners in a formed aluminum cylinder, the size of the Space Shuttle external tank, replaced machined thick plate and welding steps to eliminate > 500,000 pounds of machining chips and ~ 0.5 miles of welds. The flow forming method, called the Integrally Stiffened Cylinder (ISC) process, was successfully demonstrated up to the 10-foot diameter scale, which laid the groundwork for the current investigation of metallic fuselage structures. Using the ISC process as the basis for the re-design of a metallic fuselage eliminates hundreds of thousands of holes and rivets, while significantly reducing assembly time and crack initiation sites in the integral structure. However, the ISC process is not currently configured to fabricate circumferential ring frames for carrying fuselage internal pressure loads. Consequently, a trade study was performed to assess existing and advanced manufacturing processes, including additive manufacturing, forming, and welding. The approach with the lowest barriers to success, while simultaneously improving manufacturing time and cost, was to use formed ring frame segments attached to the ISC via Refill Friction Stir Spot Welding (RFSSW). The RFSSW process is five times faster than drilling, reaming, and riveting and provides similar mechanical performance. Finishing the fuselage structure with conventional windows, floor beams, and floor panels can then be accomplished using incumbent assembly methods, thereby maximizing reuse of existing infrastructure for aircraft construction. Structural analyses were performed to assess and optimize the geometric variables of integrated skin and stiffener configurations. A cost benefit and manufacturing rate analysis was also performed to compare against the current state-of-the-art for single aisle transport class aircraft. The resulting structure offers a weight reduction that rivals current graphite-epoxy composite fuselage structures. The projected manufacturing rate is close to double current metallic fuselages and six times faster than current composite manufacturing practices. The damage tolerance properties of a monocoque fuselage structure have yet to be assessed, but past integral airframe structural work has exploited geometric features to blunt or turn cracks. This concept offers promise that integrated structures can meet stringent aircraft durability specifications. An important benefit is that such aluminum fuselage structures may be inspected and repaired using established practices and existing expertise. Finally, pursuit of advanced manufacturing processes for future aluminum fuselages minimizes waste and the structure is 100% recyclable at the end-of-life for maximum sustainability.
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.
Research at Langley AFB concerning automated space assembly is reviewed, including a Space Shuttle experiment to test astronaut ability to assemble a repetitive truss structure, testing the use of teleoperated manipulators to construct the Assembly Concept for Construction of Erectable Space Structures I truss, and assessment of the basic characteristics of manipulator assembly operations. Other research topics include the simultaneous coordinated control of dual-arm manipulators and the automated assembly of candidate Space Station trusses. Consideration is given to the construction of an Automated Space Assembly Laboratory to study and develop the algorithms, procedures, special purpose hardware, and processes needed for automated truss assembly.
The impact on the design and operation of an automated structure assembler of requiring the assembler to also install the platform electrical and/or fluid utility circuits was examined. Possible utility requirements were defined and examined in conjunction with the automated assembler. Preliminary concepts are presented which permit the electrical and fluid circuits to be installed with the structural elements.