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This paper presents and overview of the telerobotic research and development activities underway at the Jet Propulsion Laboratory in support of NASA thrusts in telerobotic servicing of free flying satellites and platforms, planetary exploration, and dual use technologies enhancing both NASA ground applications and commercial competitiveness.
Space Shuttle's Remote Manipulator System (Canadarm) is a 50 foot robot arm used to deploy, retrieve or repair satellites in orbit. Initial spinoff version is designed to remove, inspect and replace large components of Ontario Hydro's CANDU nuclear reactors, which supply 50 percent of Ontario Hydro's total power reduction. CANDU robot is the first of SPAR's Remote Manipulator Systems intended for remote materials handling operations in nuclear servicing, chemical processing, smelting and manufacturing. Inco Limited used remote manipulator for remote control mining equipment to enhance safety and productivity of Inco's hardrock mining operations. System not only improves safety in a hazardous operation that costs more than a score of lives annually, it also increases productivity fourfold. Remote Manipulator System Division is also manufacturing a line of industrial robots and developing additional system for nuclear servicing, mining, defense and space operations.
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.
The goal of our program is to develop, integrate and demonstrate the science and technology of remote telerobotics leading to increases in operational capability, safety, cost effectiveness and probability of success of NASA missions. To that end, the program fosters the development of innovative system concepts for on-orbit servicing and planetary surface missions which use telerobotic systems as an important central component. These concepts are carried forward into develoments which are used to evaluate and demonstrate technology in realistic flight and ground experiments.
The Tile Automation System includes applications of automation and robotics technology to all aspects of the Shuttle tile processing and inspection system. An integrated set of rapid prototyping testbeds was developed which include speech recognition and synthesis, laser imaging systems, distributed Ada programming environments, distributed relational data base architectures, distributed computer network architectures, multi-media workbenches, and human factors considerations. Remote voice training in the Tile Automation System is discussed. The user is prompted over a headset by synthesized speech for the training sequences. The voice recognition units and the voice output units are remote from the user and are connected by Ethernet to the main computer system. A supervisory channel is used to monitor the training sequences. Discussions include the training approaches as well as the human factors problems and solutions for this system utilizing remote training techniques.
This paper describes development and demonstration of remote crawling systems to support periodic examinations of interim dry storage system (DSS) canisters for spent nuclear fuel in the USA. Specifically, this work relates to robotic crawler developments for “canister” based DSS systems which form the majority population of DSSs, in the USA, for interim storage of spent nuclear fuel. Consideration of potential degradation of the welded stainless-steel canister in these systems is required for continued usage in the period of extended operation (PEO) beyond their initial licensed or certified terms. Challenges associated with performing the periodic examinations are associated with physical access to the canister surface which is constrained due to narrow annulus spaces between the canister and the overpack, tortuous entry pathways, and high temperatures and radiation doses that can be damaging to materials and electronics. Motivations for performing periodic examinations and developing robotic crawlers for performing those examinations remotely will be presented and several activities to demonstrate robotic crawlers for different DSS systems are summarized.
In the aftermath of the space shuttle Columbia accident, it quickly became clear that new methods would need to be developed that would provide the capability to inspect and repair the shuttle's thermal protection system (TPS). A boom extension to the Remote Manipulator System (RMS) with a laser topography sensor package was identified as the primary means for measuring the damage depth in acreage tile as well as scanning Reinforced Carbon- Carbon (RCC) surfaces. However, concern over the system's fault tolerance made it prudent to investigate alternate means of acquiring close range photographs and contour depth measurements in the event of a failure. One method that was identified early was to use the Simplified Aid For EVA Rescue (SAFER) propulsion system to allow EVA access to damaged areas of concern. Several issues were identified as potential hazards to SAFER use for this operation. First, the ability of an astronaut to maintain controlled flight depends upon efficient technique and hardware reliability. If either of these is insufficient during flight operations, a safety tether must be used to rescue the crewmember. This operation can jeopardize the integrity of the Extra-vehicular Mobility Unit (EMU) or delicate TPS materials. Controls were developed to prevent the likelihood of requiring a tether rescue, and procedures were written to maximize the chances for success if it cannot be avoided. Crewmember ability to manage tether cable tension during nominal flight also had to be evaluated to ensure it would not negatively affect propellant consumption. Second, although propellant consumption, flight control, orbital dynamics, and flight complexity can all be accurately evaluated in Virtual Reality (VR) Laboratory at Johnson Space Center, there are some shortcomings. As a crewmember's hand is extended to simulate measurement of tile damage, it will pass through the vehicle without resistance. In reality, this force will push the crewmember away from the vehicle, and could induce a moment which, if strong enough, could saturate the attitude control system in SAFER. This raises the concern that additional propellant will be consumed to maintain controlled flight. To account for this, the fidelity of the Virtual Reality simulation was improved to include the effect of crewmember contact with the vehicle during SAFER flight. In addition, while participating in VR simulations, the subject is in shirt sleeves and sits in a chair. This does not provide a flight-like representation of body position awareness. To prevent inadvertent contact with tile or RCC, other facilities were utilized to establish crew preferences for body attitude and tool configuration. Finally, a study was performed to determine if attitude constraints are needed for the Space shuttle and International Space Station to reduce SAFER flight difficulty.
Simulation and visualization of rover behavior are critical capabilities for scientists and rover operators to construct, test, and validate plans for commanding a remote rover. The VIPER system links these capabilities. using a high-fidelity virtual-reality (VR) environment. a kinematically accurate simulator, and a flexible plan executive to allow users to simulate and visualize possible execution outcomes of a plan under development. This work is part of a larger vision of a science-centered rover control environment, where a scientist may inspect and explore the environment via VR tools, specify science goals, and visualize the expected and actual behavior of the remote rover. The VIPER system is constructed from three generic systems, linked together via a minimal amount of customization into the integrated system. The complete system points out the power of combining plan execution, simulation, and visualization for envisioning rover behavior; it also demonstrates the utility of developing generic technologies. which can be combined in novel and useful ways.
The retrieval command subsystem reference manual for the NASA Aerospace Safety Information System (NASIS) is presented. The output oriented classification of retrieval commands provides the user with the ability to review a set of data items for verification or inspection as a typewriter or CRT terminal and to print a set of data on a remote printer. Predefined and user-definable data formatting are available for both output media.
Proposed computerized video system processes images of fluorescent dyes absorbed in flaws in welds. Video camera, held by operator or by remote manipulator, views weld illuminated by visible white and ultraviolet light. Images of penetrating dye in cracks and voids in weld joint appear on video monitor. Fluorescent features enhanced by software to facilitate identification of true flaws and record important data.
The use of remotely transmitted data from a nuclear facility under international nuclear safeguards to an inspectorate headquarters has been rapidly growing since inception as its value in reducing inspection effort and cost is demonstrated. There are opportunities for further growth moving forward including (1) the number of spent fuel casks in dry interim storage are increasing, leading to strain on inspection resources and potentially increased radiation exposure to inspectors, (2) the frequency of encapsulating spent nuclear fuel for final disposal in geological repositories occurs at a rate that may lead to the need for on-site inspectors unless systems can be developed to remotely transmit data, and (3) new facility types such as small modular reactors may rely heavily on remotely transmitted data due in part to remote locations of operation and mobility. Challenges need to be addressed too and include (1) hesitancy to implement remote data transmission by states, (2) data collection, transmission, security, and analysis, and (3) reliable power and communications. This report examines the evolution, equipment deployed, status, and opportunities/challenges of remote data transmission moving forward.
Boiler failure could cause loss of life and safety issues, cost hundreds of thousands of dollars in equipment repairs, property damage and production losses, and drive up the cost of electric power. Boiler maintenance is challenging and risky for inspectors working on scaffolding in confined hazardous spaces inside of a boiler and sometimes the space is hard to access. The operation is also time-consuming due to the large area of vertical structures for inspection and the tremendous effort needed for scaffolding. Recently, the use of robotics (e.g., drones and crawlers) in power plants for maintenance is growing rapidly. However, the existing robotics solutions show two notable technological gaps: no live repair capability, and no Artificial Intelligence (AI) for smart autonomy. The objective of this project is to develop an integrated autonomous robotic platform that is equipped with compact non-destructive evaluation (NDE) sensors to perform live inspection, operates onboard repair devices to perform live repair, and uses AI for intelligent data fusion and predictive analysis for automated and smart spatiotemporal inspection, analysis and repair of the furnace walls in coal-fired boilers. The approach to achieve the objective includes developing NDE sensors with signal processing techniques, designing and evaluating repair devices for robots based on fusion and solid-state technologies, and an autonomous robotic platform that can attach to and navigate on boiler furnace walls using magnetic drive tracks. The robot is also powered by AI to automate data gathering (e.g., 3D mapping and damage localization) and predictive analysis. This project has advanced the state-of-the-art by providing technological breakthroughs including compact NDE and repair tools for robots, AI capabilities for smart autonomy, and a robotic platform for automated boiler maintenance. This project has great potential to result in significant benefits including limiting or eliminating the need to send operators to assess difficult-to-access or hazardous areas, enabling automated live inspection and repair, avoiding time consuming scaffolding (especially for partial maintenance during unplanned outage), collecting comprehensive and well-organized data smartly, and avoiding or limiting the need for onsite or remote piloting technicians. The impacts can be tremendous in terms of the time and cost savings, reducing the risk for human operators, and increasing boiler reliability, usability, and efficiency. In addition, by developing the new technologies on the autonomous inspection and repair robot, by involving multiple undergraduate and graduate students working together with the faculty members on this project, and by generating knowledge and building up collaborations with industrial partners, this effort will significantly update the education capabilities, support long-term fundamental research, and maintain the leadership of Colorado School of Mines and Michigan State University in energy fields.
An Interactive Cluster Analysis Procedure (ICAP) was developed to derive classifier training statistics from remotely sensed data. ICAP differs from conventional clustering algorithms by allowing the analyst to optimize the cluster configuration by inspection, rather than by manipulating process parameters. Control of the clustering process alternates between the algorithm, which creates new centroids and forms clusters, and the analyst, who can evaluate and elect to modify the cluster structure. Clusters can be deleted, or lumped together pairwise, or new centroids can be added. A summary of the cluster statistics can be requested to facilitate cluster manipulation. The principal advantage of this approach is that it allows prior information (when available) to be used directly in the analysis, since the analyst interacts with ICAP in a straightforward manner, using basic terms with which he is more likely to be familiar. Results from testing ICAP showed that an informed use of ICAP can improve classification, as compared to an existing cluster analysis procedure.
Transient thermography, which employs pulse surface heating of an inspected component followed by acquisition of the thermal decay stage, is gaining wider acceptance as a result of its remoteness and rapidness. Flaws in the component s material may induce a thermal contrast in surface thermograms. An important issue in transient thermography is estimating the depth of a subsurface flaw from the thermal response. This improves the quantitative ability of the thermal evaluation: from one scan it is possible to locate regions of anomalies in thickness (caused by corrosion) and estimate the implications of the flaw on the integrity of the structure. Our research focuses on thick composite aircraft components. A long square heating pulse and several minutes observation period are required to receive an adequate thermal response from such a component. Application of various time-related informative parameters of the thermal response for depth estimation is discussed. A three-dimensional finite difference model of heat propagation in solids in Cartesian coordinates is used to simulate the thermographic process. Typical physical properties of polymer graphite composites are assumed for the model.
With the advent of complex space structures (i.e., U.S. Space Station), the need for methods for remotely detecting structural damage will become greater. Some of these structures will have hundreds of individual structural elements (i.e., strut members). Should some of them become damaged, it could be virtually impossible to detect it using visual or similar inspection techniques. The damage of only a few individual members may or may not be a serious problem. However, should a significant number of the members be damaged, a significant problem could be created. The implementation of an appropriate remote damage detection scheme would greatly reduce the likelihood of a serious problem related to structural damage ever occurring. This report presents the results of the research conducted on remote structural damage detection approaches and the related mathematical algorithms. The research was conducted for the Small Business Innovation and Research (SBIR) Phase 2 National Aeronautics and Space Administration (NASA) Contract NAS7-961.
A two phase approach was undertaken to: (1) evaluate the performance of a general-purpose anthropomorphic manipulator with various controllers and display arrangements, (2) identify basic technical limitations of existing teleoperator designs, and associated controls and displays, and (3) identify, through experimentation, the effects that controls and displays have on the performance of an anthropomorphic manipulator. In Phase 1 the NASA-furnished manipulators, controls and displays were integrated with the remote maneuvering unit; in Phase 2 experiments were defined and performed to assess the utility of teleoperators for 6 typical space inspection, maintenance and repair tasks.
At JPL, a <5 kg free-flying micro-inspector spacecraft is being designed for host-vehicle inspection. The spacecraft includes a hazard avoidance sensor to navigate relative to the vehicle being inspected. Structured light was selected for hazard avoidance because of its low mass and cost. Structured light is a method of remote sensing 3-dimensional structure of the proximity utilizing a laser, a grating, and a single regular APS camera. The laser beam is split into 400 different beams by a grating to form a regular spaced grid of laser beams that are projected into the field of view of an APS camera. The laser source and the APS camera are separated forming the base of a triangle. The distance to all beam intersections of the host are calculated based on triangulation.
Additive manufacturing (AM) is revolutionizing the production of custom components with complex internal geometries, essential for high-performance applications in diverse fields such as medicine and defense. These AM parts optimize strength while minimizing weight by utilizing internal lattice structures consisting of large quantities of small interconnected struts. However, the complexity of these structures, combined with the challenges of using X-ray Computed Tomography (XCT) data, makes validation of part reliability difficult. This ultimately inhibits the development of novel parts for our collaborating material scientists. Here, we introduce LatticeAnalytics, a novel framework specifically designed for visual inspection of defects in these lattice structures. Our framework offers an end-to-end solution that includes the data management of XCT scans, enables remote access for geographically dispersed teams through a web-based dashboard, and incorporates novel visualizations. Our analysis is facilitated by a coarse alignment between the lattice’s nominal model, a spatial graph, and the XCT data. We employ a simple VR-based approach for fast and rough alignment, followed by an offline registration and identification of the struts. With the nodes and struts aligned and identified in the volume, our framework allows querying of subvolumes containing a single strut at multiple resolutions. This avoids computation over the entire lattice and also allow for easy parallelization of down-stream computations, such as strut-specific metrics. To depict a fast overview of the strut quality, we introduce two innovative visual encodings, crucial for our collaborators’ research in creating novel AM parts: the Contour View and the Roughness Map, which depict critical geometrical and surface features of individual struts in standardized two 2D views. We evaluated the integrated system through expert interviews. The feedback confirms the framework’s practicality and its effectiveness in enhancing current inspection workflows. It solves major bottlenecks for our collaborators, ultimately helping them create novel parts with advanced properties.