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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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All sourcesNASA NTRSDOE OSTI
NASA NTRSDate not supplied

Investigating Laser Beam Welding as an In-Space Joining Technique via Thermal Vacuum and Microgravity and Vacuum Experiments

In-space joining technologies are crucial for stimulating an in-space economy and for enabling sustained space exploration by in-space manufacturing and repair of metallic structures. Compared to brazing or soldering, in-space welding (ISW) can provide highly hermetic, strong, and complex joints, potentially without introducing additional material. However, the influence of extreme temperatures, reduced pressure, and reduced gravity on ISW is not yet fully elucidated. Several efforts at NASA are investigating laser beam welding (LBW) as a joining and repair method in both thermal vacuum (TVAC) and combined vacuum & reduced gravity environments. NASA Marshall Space Flight Center (MSFC) shepherded several ISW projects in its past, including the 1973 electron beam welding on Skylab, the 1989 low-power LBW on parabolic flights, and the unflown 1990s-era In-Space Welding Experiment. Recent parabolic flights and 3 degree-of-freedom ground testing build upon this heritage. A collaboration with the Ohio State University using NASA Langley Research Center (LaRC) hardware retrofitted for LBW achieved the first high-powered laser welds under vacuum and low gravity and developed a workforce capable developing such experimental hardware. A ground testing campaign at the MSFC Flat Floor simulated fit-up and welding representative of ISW in 3 degrees of freedom to emulate microgravity effects on inertial systems. One ongoing effort is a NASA Early Career Initiative project – Lunar Assembly and Servicing by Autonomous Robotics (LASAR). Ruggedized LBW components were developed by an external partner for use in TVAC. A TVAC-rated robotic arm was procured by MSFC and used in the first known robotic laser weld where all components save the laser generator were under vacuum. NASA Johnson Space Center (JSC) is advancing supervised autonomy of ISW. NASA LaRC continues to adapt their unique snowflake joint geometry, suitable for connecting segments in trusses and other structures, to LBW. Upcoming TVAC campaigns will focus on testing extreme temperatures, proving out autonomous operations, and demonstrating weld repair. Weld inspection will occur via a non-contact nondestructive evaluation (NDE) technique – electromagnetic acoustic transduction (EMAT). Another ongoing effort based at MSFC is the DISCMAN -- DIsk-Shaped Configurable and Modular vAcuum uNit – which seeks to development a compact, modular payload that can provide a vacuum environment while in a reduced gravity condition. This payload could support multiple in-space manufacturing developmental efforts, with the first demonstration technology being LBW. Currently, the design is targeting operations in the pressurized volume of a space station, but the payload could readily be adapted to other flight platforms such as parabolic or even suborbital vehicles. LASAR elucidates the effects of temperature and vacuum on LBW while DISCMAN probes those of vacuum and gravity. Through these complementary efforts, NASA is addressing the primary challenges of ISW across the space environment while simultaneously developing and maturing technologies including robotic systems and inspection methodologies for future practical implementation on the Moon and beyond. This approach is timely, as upcoming missions requiring sustained human presence in space will depend on reliable ISW capabilities to create robust metallic joints currently unproven in the space environment and to perform repairs in situ .

hypogravity↗
NASA NTRS1984

Systems view of power systems autonomy

A Space Station will involve the formation and sustained operation of an assembly of humans and machines in space for a period of 10-20 years. Technology and mission studies of a permanently manned, evolutionary Space Station have identified the need for automated and eventually some degree of autonomous systems operation. A Space Station power system will have a high degree of interaction with other onboard systems which will act as power loads. By examining the evolution of an operational power system from a systems viewpoint through increasing degrees of automation the system and technology requirements are identified for an evolutionary system.

Anderson, J. L.↗
NASA NTRS2023

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↗
NASA NTRSDate not supplied

Conjunction Assessment and Deconfliction Paradigm for Co-Located Satellite Constellations With on-Spacecraft “Autonomous” Flight Dynamics Control

Satellite constellations that employ on-spacecraft flight dynamics and conjunction assessment (CA) approaches face particular challenges. First, they must arrange to obtain and upload to the constellation satellite close approach information, such as Conjunction Data Messages, so that their on-board systems will have the data they need to make informed CA decisions. Second, given current latencies in obtaining CA screening information, such systems often cannot obtain dedicated screenings of their proposed maneuvers before they are executed. Third, they usually cannot engage in real time with owner/operators (O/Os) with whom they may come into conjunction, relying instead on pre-arranged courses of action that may or may not fit a given situation well. Despite these difficulties, it is nonetheless possible, as operators such as SpaceX have demonstrated, to operate safely using on-board CA calculations, in the presence of a largely collaborative operating environment. The situation breaks down, however, when two constellations that operate with such a paradigm are placed in the same orbital region and will experience conjunctions with each other. Each may have a vague idea of where the other’s satellites are, or perhaps even a somewhat precise idea if they exchange O/O ephemerides, but neither will know the other’s more immediate maneuver intentions, especially for situations in which they are in a high-risk conjunction with each other and a mitigation maneuver is required. As there is no formalized way for these automated systems to ascertain each other’s intentions for this type of conjunction, it is quite possible that each spacecraft may choose a maneuver that results in the two objects’ colliding. An opportunity to develop a solution to this problem was presented by the NASA “Starling” project, a small experimental constellation developed to demonstrate autonomous satellite control and constellation reconfiguration and for which a launch was obtained that, serendipitously, will place this constellation close to the SpaceX Starlink constellation. Because the NASA constellation is experimental, an extended mission part of the mission has been negotiated to implement and test mechanisms for resolving the problem of co-located constellations with on-board flight dynamics control. For the last eighteen months, a consortium among NASA Ames (the Starling satellite providers), NASA CARA (the Agency organization responsible for conjunction assessment), Space X, and the Department of Commerce (in observer status) has met regularly to assemble a concept of operations for a robust solution to this problem and has developed a prototype ground node that will serve as a needed CA screening and information dispensary. The approach and methods, as well as the active employment of the developed ground node, will be tested both in simulation before actual use and then in actual spacecraft operations, which are anticipated to begin in January 2024. This paper will describe the co-located autonomously-controlled constellation problem and the developed solution in detail, outlining what ground node (i.e., government) infrastructure and features are required, what particular capabilities are needed by the constellations themselves in order to make use of this deconfliction paradigm, and the migration path forward to allow such a capability set to be incorporated by the Department of Commerce’s space traffic coordination system.

Conjunction Assessment↗
NASA NTRS2005

Behavior-based multi-robot collaboration for autonomous construction tasks

The Robot Construction Crew (RCC) is a heterogeneous multi-robot system for autonomous construction of a structure through assembly of Long components. The two robot team demonstrates component placement into an existing structure in a realistic environment. The task requires component acquisition, cooperative transport, and cooperative precision manipulation. A behavior-based architecture provides adaptability. The RCC approach minimizes computation, power, communication, and sensing for applicability to space-related construction efforts, but the techniques are applicable to terrestrial construction tasks.

autonomous construction↗
NASA NTRS1989

Control of free-flying space robot manipulator systems

Control techniques for self-contained, autonomous free-flying space robots are being tested and developed. Free-flying space robots are envisioned as a key element of any successful long term presence in space. These robots must be capable of performing the assembly, maintenance, and inspection, and repair tasks that currently require astronaut extra-vehicular activity (EVA). Use of robots will provide economic savings as well as improved astronaut safety by reducing and in many cases, eliminating the need for human EVA. The focus of the work is to develop and carry out a set of research projects using laboratory models of satellite robots. These devices use air-cushion-vehicle (ACV) technology to simulate in two dimensions the drag-free, zero-g conditions of space. Current work is divided into six major projects or research areas. Fixed-base cooperative manipulation work represents our initial entry into multiple arm cooperation and high-level control with a sophisticated user interface. The floating-base cooperative manipulation project strives to transfer some of the technologies developed in the fixed-base work onto a floating base. The global control and navigation experiment seeks to demonstrate simultaneous control of the robot manipulators and the robot base position so that tasks can be accomplished while the base is undergoing a controlled motion. The multiple-vehicle cooperation project's goal is to demonstrate multiple free-floating robots working in teams to carry out tasks too difficult or complex for a single robot to perform. The Location Enhancement Arm Push-off (LEAP) activity's goal is to provide a viable alternative to expendable gas thrusters for vehicle propulsion wherein the robot uses its manipulators to throw itself from place to place. Because the successful execution of the LEAP technique requires an accurate model of the robot and payload mass properties, it was deemed an attractive testbed for adaptive control technology.

Cannon, Robert H., Jr.↗
NASA NTRS2004

A Stigmergic Cooperative Multi-Robot Control Architecture

In nature, there are numerous examples of complex architectures constructed by relatively simple insects, such as termites and wasps, which cooperatively assemble their nests. A prototype cooperative multi-robot control architecture which may be suitable for the eventual construction of large space structures has been developed which emulates this biological model. Actions of each of the autonomous robotic construction agents are only indirectly coordinated, thus mimicking the distributed construction processes of various social insects. The robotic construction agents perform their primary duties stigmergically, i.e., without direct inter-agent communication and without a preprogrammed global blueprint of the final design. Communication and coordination between individual agents occurs indirectly through the sensed modifications that each agent makes to the structure. The global stigmergic building algorithm prototyped during the initial research assumes that the robotic builders only perceive the current state of the structure under construction. Simulation studies have established that an idealized form of the proposed architecture was indeed capable of producing representative large space structures with autonomous robots. This paper will explore the construction simulations in order to illustrate the multi-robot control architecture.

Howsman, Thomas G.↗
NASA NTRS1986

Telerobotic assembly of space station truss structure

Discussed are methods of assembling the space station's structure utilizing only telerobotic devices, i.e.: (1) an approximately anthropomorphic telerobot with two dextrous arms; (2) the Shuttle Remote Manipulator System (SRNS); (3) various material handling machines. Timelines and task recommendations for autonomous operations are also included. Also described are some experimental results comparing two manipulator control devices.

Fischer, Grahme↗
NASA NTRS2000

In-Space Transportation for Geo Space Solar Satellites

Space solar power satellites have the potential to provide abundant quantities of electricity for use on Earth. One concept, the Sun Tower, can be assembled in geostationary orbit from pieces transferred from Earth. The cost of transportation from Earth is one of the major hurdles to space solar power. This study found that a two-stage rocket launch vehicle with autonomous solar-electric transfer can provide the transportation at prices close to the goal of $800/kg

Martin, James A.↗
NASA NTRS1987

Telerobotic assembly of space station truss structures

Discussed here are methods of assembling the space station's structure utilizing only telerobotic devices, i.e.: (1) an approximately anthropomorphic telerobot with two dextrous arms; (2) the Shuttle Remote Manipulator System (SRMS); and (3) various material handling machines. Timelines and task recommendations for autonomous operations are also included. Also described are some experimental results comparing two manipulator control devices.

Fischer, G.↗
NASA NTRS2005

Behavior-Based Multi-Robot Collaboration for Autonomous Construction Tasks

We present a heterogeneous multi-robot system for autonomous construction of a structure through assembly of long components. Placement of a component within an existing structure in a realistic environment is demonstrated on a two-robot team. The task requires component acquisition, cooperative transport, and cooperative precision manipulation. Far adaptability, the system is designed as a behavior-based architecture. Far applicability to space-related construction efforts, computation, power, communication, and sensing are minimized, though the techniques developed are also applicable to terrestrial construction tasks.

autonomous construction↗
DOE OSTI2026

Robotics for Energy Infrastructure Construction on Earth and Beyond: Pilot Study Exploring Level 3-4 Semi-Autonomous Installation of a Reduced-Scale Photovoltaic Power Plant Prototype: Preprint

There is a growing need to build energy infrastructure at massive scale on both Earth and in space. On Earth, increasing electricity demand from applications such as AI data centers is driving rapid expansion of power systems, while in space, long-duration missions such as lunar operations require reliable and resilient energy infrastructure that can be deployed quickly. These needs outpace the capabilities of conventional construction methods. Robotic construction offers a path to faster, lower-cost, and more consistent deployment, yet most existing approaches focus on automating individual tasks rather than end-to-end assembly. The Industrialized Construction Innovation (ICI) team at the National Laboratory of the Rockies (NLR), in collaboration with the Colorado School of Mines, has been investigating robotics and automation strategies for rapid end-to-end energy infrastructure construction. This paper presents a pilot study demonstrating level 3-4 semi-autonomous, end-to-end robotic assembly of a reduced-scale photovoltaic power plant prototype under terrestrial conditions. The approach combines hardware redesign of photovoltaic components for robotic compatibility, discrete-event and physics-based robotic simulations in synthetic environments, and sim-to-real deployment to execute end-to-end robotic assembly of[NM1.1][NM1.2] tracking components, structural members, photovoltaic modules, and embedded electrical connections. The pilot identifies key limitations like tolerance management, perception and localization, end effector capability, fastening methods, and multi-physics simulation fidelity, that must be addressed to enable end-to-end robotic assembly of full-scale energy infrastructure. The study highlights how these insights inform scaling strategies for terrestrial energy infrastructure and adaptation to unstructured and extreme environments, including off-world scenarios such as robotic assembly of vertical tall lunar towers.

14 SOLAR ENERGY↗
NASA NTRS1984

Multi-100kW: Planar low cost solar array development

Seven low cost multi-100 kW planar solar array modules were fabricated and tested. Two different designs were used, demonstrating advanced solar array construction practices. Both module types utilized second generation gridded back cells featuring high efficiency and IR transparency. A silicon dioxide AR coating optimized for transmission at gamma = 1.7 microns was applied to the back surface. Two interconnect types, a single sheet printed circuit and a roll type, with alternate approaches to increasing transparency and reducing cost were designed and fabricated. Hinge stress and electrical power optimization were also examined. Two point designs were studied. The first design used a coilage longeron mast and is autonomously deployable. The second design used a Stac Beam for high natural frequency response and required astronaut assistance and assembly on orbit. It was conclusively demonstrated that planar arrays are the most cost effective design for use on the space station or other high power applications.

Source record↗
NASA NTRS1994

Robotic technologies of the Flight Telerobotic Servicer (FTS) including fault tolerance

The original FTS concept for Space Station Freedom (SSF) was to provide telerobotic assistance to enhance crew activity and safety and to reduce crew EVA (Extra Vehicular Activity) activity. The first flight of the FTS manipulator systems would demonstrate several candidate tasks and would verify manipulator performance parameters. These first flight tasks included unlocking a SSF Truss Joint, mating/demating a fluid coupling, contact following of a contour board, demonstrating peg-in-hole assembly, and grasping and moving a mass. Future tasks foreseen for the FTS system included ORU (Orbit Replaceable Unit) change-out, Hubble Space Telescope Servicing, Gamma Ray Observatory refueling, and several in-situ SSF servicing and maintenance tasks. Operation of the FTS was planned to evolve from teleoperation to fully autonomous execution of many tasks. This wide range of mission tasks combined with the desire to evolve toward fully autonomy forced several requirements which may seen extremely demanding to the telerobotics community. The FTS requirements appear to have been created to accommodate the open-ended evolution plan such that operational evolution would not be impeded by function limitations. A recommendation arising from the FTS program to remedy the possible impacts from such ambitious requirements is to analyze candidate robotic tasks. Based on these task analyses, operational impacts against development impacts were weighed prior to requirements definition. Many of the FTS requirements discussed in the following sections greatly influenced the development cost and schedule of the FTS manipulator. The FTS manipulator has been assembled at Martin Marietta and is currently in testing. Successful component tests indicate a manipulator which achieves unprecedented performance specifications.

Chladek, John T.↗
NASA NTRS1984

Computer vision for real-time orbital operations. Center directors discretionary fund

Machine vision research is examined as it relates to the NASA Space Station program and its associated Orbital Maneuvering Vehicle (OMV). Initial operation of OMV for orbital assembly, docking, and servicing are manually controlled from the ground by means of an on board TV camera. These orbital operations may be accomplished autonomously by machine vision techniques which use the TV camera as a sensing device. Classical machine vision techniques are described. An alternate method is developed and described which employs a syntactic pattern recognition scheme. It has the potential for substantial reduction of computing and data storage requirements in comparison to the Two-Dimensional Fast Fourier Transform (2D FFT) image analysis. The method embodies powerful heuristic pattern recognition capability by identifying image shapes such as elongation, symmetry, number of appendages, and the relative length of appendages.

Vinz, F. L.↗
NASA NTRSDate not supplied

Modeling Deformable Linear Objects for Autonomous Robotic Outfitting of Lunar Surface Systems

This paper presents structural models of deformable linear objects (DLOs). DLOs are a subclass of deformable objects that encompasses common outfitting elements such as cables and ropes. Models are validated through hardware experiments, and integration in a robotic autonomy architecture for space environments is discussed. A persistent human presence on the lunar surface is one of the next major milestones in space exploration. This requires the development of robust extraplanetary construction technologies including structures and materials modeling and robotic systems. Previous robotic construction technology development has primarily focused on structural assembly, with significantly less focus on robotically performed outfitting tasks to instantiate subsystems providing power, data, life support, etc. These tasks involve manipulation of highly flexible elements, which are difficult to model, such as cable harnesses, ropes, and hoses. Robotic manipulation of DLOs, especially cable harnesses, is an active area of research as cable harnesses are essential for providing power and data to space assets. DLO models that can be used for robot manipulator trajectory generation are necessary for autonomous operation of lunar infrastructure. There are many proposed methods for modeling DLOs, and they primarily fall into three types: 1) discrete model-based, 2) continuum model-based, and 3) Neural Network-based. These types each have pros and cons, and the tradeoff between model accuracy and computational speed informs which type should be used. An understanding of this trade-off is imperative for real-time control of autonomous systems. High computational requirements reduce the speed of the model, making real-time control difficult, while accuracy is critical to preventing collisions. Discrete models, such as a mass-spring multibody representation, require relatively few calculations, and accuracy is directly tied to the step size of the discretization. Continuum models, such as a B-spline representation or a Cosserat rod model (a mix of continuous and discrete), are more informed of the structural properties of the cable and are much more accurate than a rigid body mass-spring model, but at significant computational cost. A Neural Network approach can provide an online solution with very few computational steps, but properly generating training data can be difficult and validation for an in-space application is not trivial. This paper explores the trade-off between different modeling approaches and compares accuracy and computational speed/complexity of the three types mentioned above. Model accuracy is evaluated using a cable in a static configuration. True cable shape is obtained using a depth camera for RGB images and point-cloud segmentation. The purpose of this experiment is to evaluate the trade-offs of different approaches to the DLO modeling problem. Understanding the tradeoffs between different cable modeling techniques paves the way for developing robotic control and planning architectures necessary for real-time manipulation of DLOs for lunar infrastructure outfitting. Real-time control is required for robotic systems to be able to actively manipulate a cable in a harsh environment where model and sensor errors compound, and environmental conditions can cause significant disturbances. Cable routing must be performed in areas with high density of objects/obstacles: through truss structures, near solar panels or mirror arrays, next to bundles of electrical equipment. Understanding the best way to plan and manipulate a cable without disrupting the environment or damaging the cable is imperative to robotic outfitting operations on the lunar surface.

Amy M Quartaro↗
NASA NTRS1989

Lunar construction utility vehicle

The lunar construction utility vehicle (LCUV) is an all-purpose construction vehicle which will aid in the robotic assembly of a lunar outpost. The LCUV will have the following capabilities: (1) must be self supporting including repairs; (2) must offload itself from a lunar lander; (3) must be telerobotic and semi-autonomous; (4) must be able to transport one space station common module; (5) must allow for man-rated operation; and (6) must be able to move lunar regolith for site preparation. This study recommends the use of an elastic tracked vehicle. Detailed material analyses of most of the LCUV components were accomplished. The body frame, made of pinned truss elements, was stress analyzed using NASTRAN. A track connection system was developed; however, kinematic and stress analyses are still required. This design recommends the use of hydrogen-oxygen fuel cells for power. Thermal control has proven to be a problem which may be the most challenging technically. A tentative solution has been proposed which utilizes an onboard and towable radiator. Detailed study of the heat dissipation requirements is needed to finalize radiator sizing. Preliminary work on a man-rated cabin has begun; however, this is not required during the first mission phase of the LCUV. Finally, still in the conceptual phases, are the communication, navigation and mechanical arm systems.

Source record↗
NASA NTRS2001

Site Selection and Deployment Scenarios for Servicing of Deep-Space Observatories

The deep-space environment and relative transportation accessibility of the Weak Stability Boundary (WSB) region connecting the Earth-Moon and Sun-Earth libration points makes the Sun-Earth L2 an attractive operating location for future observatories. A summary is presented of key characteristics of future observatories designed to operate in this region. The ability to service observatories that operate within the region around the Lagrange points may greatly enhance their reliability, lifetime, and scientific return. The range of servicing missions might begin with initial deployment, assembly, test, and checkout. Post-assembly servicing missions might also include maintenance and repair, critical fluids resupply, and instrument upgrades. We define the range of servicing missions that can be performed with extravehicular activity, with teleoperated robots, and with autonomous robots. We then describe deployment scenarios that affect payload design. A trade study is summarized of the benefits and risks of alternative servicing sites, including at the International Space Station, at other low-Earth-orbit locations, at the Earth-Moon L1 location, and on-site at the Sun-Earth L2 location. Required technology trades and development issues for observatory servicing at each site, and with each level of autonomy, are summarized.

Willenberg, Harvey J.↗