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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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At least 19 records
All sourcesNASA NTRSDOE OSTI
NASA NTRS1987

Dynamic sensing of 6-axis external force and moment applied to a robot end

A dynamic force sensing method is proposed for a robot manipulator. A 6-axis wrist force sensor which is commonly used for robot force sensing does not take the direct measurement of the force and moment applied to an end effector externally from the environment of the manipulator, but takes the resultant of the gravity, the inertial force and moment on the end effector, and the external force and moment. The separation of gravitational and inertial force and moment from the measurement of the force sensor is crucial to achieving dynamically accurate force sensing and fast manipulator motion under force feedback control. A mathematical model is derived for the force sensing process and the separation of the force and moment as a nonlinear optimal state estimation problem formulated. Then an approximate solution is given using extended Kalman filtering techniques.

Yokota, Masaru Uchiyama↗
NASA NTRS1989

Performance evaluation of a 6 axis high fidelity generalized force reflecting teleoperator

A few of the results of a major study of over 100 hours of experimental teleoperation are presented. Force and torque data recorded from the robot wrist is a rich source of information on the performance of tasks. Performance measures can be computed for whole tasks, or for specific task segments. As a general principle, the performance increases as manipulation capability is increased although the effects may depend on task and performance measure. This study has laid the groundwork for much future work. Further reports will detail additional results which could not be presented here due to lack of space as well as follow-on experiments investigating manipulation under time delay and shared control conditions.

Hannaford, Blake↗
DOE OSTI2024

Automated Manufacturing of Grid Stiffened Panels with Radically Reduced Tooling

Grid stiffened continuous fiber reinforced composite panels are an attractive option for creating lightweight structures due to the tailorability for various applications and the resulting high specific properties. However, the panel stiffeners and stiffener intersections result in high tooling complexity and correspondingly high cost of implementation. These factors have limited the impact of such structures in the composites industry. Previous research has demonstrated the ability to produce high quality, high aspect ratio beams, representative of individual grid stiffeners, using E-glass/PET comingled tow via direct digital manufacturing. Further, prior preliminary efforts have demonstrated the potential to use the same approach to manufacture grid intersections that have continuous fiber in both directions. To expand on the previous efforts in grid stiffeners produced by direct digital manufacture with radically reduced tooling requirements, this effort compares two methods of providing positioning and consolidation, nozzle vs. roller. Both processes are based on a commingled yarn feedstock. The extrusion through a nozzle has been shown to enable grid intersection control through local variations in applied consolidation and serves as the baseline process. However, this approach requires a continuous placement path to create the complete grid stiffened panel as no mechanism for cutting and restarting has been implemented. Alternatively, a newly developed placement head incorporating cut and refeed, mounted to a 6-axis robot, offers the potential of improved path placement efficiency. The two techniques are used to produce similar grid composite stiffeners to evaluate the effectiveness of producing the grid intersections. Rate of deposition of the two end effectors are compared and the quality of the associated grid stiffeners, and intersections, are determined through measurement of geometry, fiber volume fraction and void fraction.

Engineering↗
DOE OSTI2022

Controls and process planning strategies for 5-axis laser directed energy deposition of Ti-6Al-4V using an 8-axis industrial robot and rotary motion

Interest in multi-axis additive manufacturing has grown significantly in recent years due to associated benefits that range from improved quality to support for greater geometric complexity. A method of 5-axis Laser Hot-Wire Directed Energy Deposition is developed and demonstrated in this study using an 8-axis industrial robot, comprised of a 6-axis serial link robot and a 2 degree-of-freedom positioner. Coordinated 5-axis motion is used to print Ti-6Al-4V objects predominantly through build plate rotation. Methods of slicing and toolpath generation are presented, including the use of an alternating toolpath direction philosophy and the manipulation of the CAD model surface normal vectors for determining the required build plate tilt angles for maintaining consistent deposition orientations relative to gravity. Another objective of the study was to determine the limits of conventional slicing and layer height control techniques for printing geometries with significant unsupported overhangs. A comparison is made between the behavior of normal and conformal bead alignment in this regard, and the performance of the layer height controller is reported as it relates to process stability and the limits of printing overhang geometries. Unsupported overhangs were successfully printed at 35° without build plate tilt and 45° with build plate tilt. Toolpath velocity and net-shape printing performance are reported as well, with 3D scans of the printed surfaces used for net-shape characterization. In all, the printing of three geometries is presented, including the overhang geometry, a 5-axis toolpath geometry, and a large-scale, multi-bead demonstrator part, which exceeded 500 mm in height and weighed 44 kg (97 lbs).

36 MATERIALS SCIENCE↗
DOE OSTI2024

Improving Self-Driving Labs: Quantifying System-Level Experiment Repeatability and Broadening Instrument-Level Compatibility

Modular Autonomous Research System (MARS) is a self-driving laboratory (SDL) which performs wet-lab science with peptide-lanthanide combinations in an automated and, ultimately, an autonomous manner to aid in soil analysis for domestic lithium mining. Autonomous experimentation involves automated experimentation, experiment planning, and active learning. MARS consists of a 6-axis robotic arm (UR5e) on a linear rail, pipette robots (Opentrons 2), and microplate readers. These components transport, operate on, and collect data with chemical solutions in standard labware. For effective autonomy, MARS must perform system-level labware operations repeatably, plan experiments autonomously, and be portable between research-domains. Repeatability is evaluated by labware placement precision, such that future operations can properly locate labware, as well as the elapsed time, so that low variance mean estimates of experiment duration can inform high-level researcher decision making. Autonomous experiment planning is the next step to decouple experimentation from human management; however, there is a conflict between the ideal system-level experiment goals and the constraints imposed by instruments’ limitations. Sub-domain portability is a long-term goal to extend MARS’ research beyond the chemistry of peptide-lanthanide binding to other sub-domains without having to invest significant overhead to system retrofitting. To address these goals, we manually trained the robotic arm labware placement and modelled statistical failurerate and uncertainty Additionally, we benchmarked the duration and variance of each experiment sub-operation as a heuristic for research decision making. Next, we use a parameterized geometric program (PGP) approach to design experiments that optimize system-level objectives and satisfy instrument-level constraints. Lastly, we proposed a Python framework to maximize MARS’ extensibility to other scientific sub-domains through a JSON-based experiment specification.

36 MATERIALS SCIENCE↗
DOE OSTI2025

Integrating Machine-learning-assisted Computer Vision with RICH System

Developments in artificial intelligence have vastly expanded the capabilities of robots. Currently, the Spallation Neutron Source (SNS) beamlines at Oak Ridge National Lab (ORNL) have robotic sample loaders to increase the efficiency of running experiments. However, they require retraining if anything about the situation changes, e.g., where the samples are, and cannot notice if errors occur. So, the viability of using computer vision and machine learning to enhance these sample loaders’ functionality was investigated. In this project, the RICH system with a Dobot CR3 6-axis robot present at the VULCAN beamline assisted by an Intel Realsense D435i camera, a unique camera that enables convenient translation of 2D pixel coordinates to 3D world points, was programmed to load ceramic crucibles into a thermogravimetric analyzer (TGA) furnace. An algorithm was constructed in Python with three major phases planned: (1) obtaining a sample, (2) moving it to the target location, and then (3) bringing the sample back to its original location once the experiment finished. In the first phase, the algorithm would dynamically detect sample locations using ArUco markers to recognize the samples’ general location and a custom-trained yolov5 object detection model to locate the crucibles’ centers. Afterward, the robot would be directed to pick up samples based on the crucibles’ calculated positions. In the second phase, the robot would move the sample to a secondary point, reorient its grip, and place the sample at the target location. In the final phase, the robot would determine whether the sample was intact and would bring it back to its original place if it was or raise an alarm. Using this algorithm, the robot was able to pick up different types of crucibles at varying positions. These results indicate that integrating machine-learning-assisted computer vision with robotic sample loaders can result in effective autonomous detection of samples.

97 MATHEMATICS AND COMPUTING↗
DOE OSTI2023

Robotic Systems integration for cleanroom SRF assembly at Fermilab

Superconducting Radio Frequency (SRF) cryomodule assembly is a critical process that demands the highest levels of contamination control in a cleanroom to ensure product quality and reliability. Within the cleanroom environment, human-driven activities remain the major source of uncontrolled particulate. Moreover, the precise manual alignment of components often exceeds expected timeframes, increasing the risk of particulate migration into the critical inner space of the SRF resonant cavity, and causing extended discomfort for workers. Automation comes as a natural solution to address these challenges. The goal of this activity is to set up and integrate a robotic system to support cavity coupler installation in the cleanroom environment. Initially, remote control of a 6-axis collaborative robot arm will be implemented as an introductory step towards automation in the cleanroom. Subsequently, the system will be further enhanced by integrating manipulation capabilities through an appropriate end-effector, and computer vision technology to enable accurate pose estimation. This comprehensive approach aims to achieve a fully automated and adaptable assembly process in the partially structured cleanroom environment, thereby enhancing efficiency and mitigating existing challenges for better product quality and workers safety.

42 ENGINEERING↗
NASA NTRS1992

Microgravity isolation mounts based upon Piezoelectric film

The topics are presented in viewgraph form and include the following: a polyvinylidene fluoride (PVDF) actuator; a semi-active soft mount; a 3-axis experiment; low frequency disturbance attenuation; the control problem; and a 6-axis laboratory prototype.

Vonflotow, Andreas↗
NASA NTRS1991

Gripper for truss structure assembly

The CIRSSE two-finger gripper is designed to be used with a 6-axis wrist-mounted force-torque sensor as part of an experimental testbed for cooperative robotic manipulation. The gripper system consists of a dedicated controller and a pneumatic powered gripper that is servoed in position or grasping force. The gripper also has a between fingertip light beam sensor. The major features of this new design are: high grasping force to weight ratio (25::1) and compactness (14 cm base-fingertip, 0.8 kilograms); low cost dedicated slave controller; and simple host-controller communications protocol to minimize command interpretation delay. Shared software functions between the host and the controller processor permit the host to select servo mode, servo gain-parameter values, and calibration offsets. Hidden primitive self-test, calibration and servo confidence functions are included.

Kelley, Robert B.↗
NASA NTRS1990

The Jet Propulsion Laboratory shared control architecture and implementation

A hardware and software environment for shared control of telerobot task execution has been implemented. Modes of task execution range from fully teleoperated to fully autonomous as well as shared where hand controller inputs from the human operator are mixed with autonomous system inputs in real time. The objective of the shared control environment is to aid the telerobot operator during task execution by merging real-time operator control from hand controllers with autonomous control to simplify task execution for the operator. The operator is the principal command source and can assign as much autonomy for a task as desired. The shared control hardware environment consists of two PUMA 560 robots, two 6-axis force reflecting hand controllers, Universal Motor Controllers for each of the robots and hand controllers, a SUN4 computer, and VME chassis containing 68020 processors and input/output boards. The operator interface for shared control, the User Macro Interface (UMI), is a menu driven interface to design a task and assign the levels of teleoperated and autonomous control. The operator also sets up the system monitor which checks safety limits during task execution. Cartesian-space degrees of freedom for teleoperated and/or autonomous control inputs are selected within UMI as well as the weightings for the teleoperation and autonmous inputs. These are then used during task execution to determine the mix of teleoperation and autonomous inputs. Some of the autonomous control primitives available to the user are Joint-Guarded-Move, Cartesian-Guarded-Move, Move-To-Touch, Pin-Insertion/Removal, Door/Crank-Turn, Bolt-Turn, and Slide. The operator can execute a task using pure teleoperation or mix control execution from the autonomous primitives with teleoperated inputs. Presently the shared control environment supports single arm task execution. Work is presently underway to provide the shared control environment for dual arm control. Teleoperation during shared control is only Cartesian space control and no force-reflection is provided. Force-reflecting teleoperation and joint space operator inputs are planned extensions to the environment.

Backes, Paul G.↗
NASA NTRS1993

The Personal Motion Platform

The Neutral Body Posture experienced in microgravity creates a biomechanical equilibrium by enabling the internal forces within the body to find their own balance. A patented reclining chair based on this posture provides a minimal stress environment for interfacing with computer systems for extended periods. When the chair is mounted on a 3 or 6 axis motion platform, a generic motion simulator for simulated digital environments is created. The Personal Motion Platform provides motional feedback to the occupant in synchronization with their movements inside the digital world which enhances the simulation experience. Existing HMD based simulation systems can be integrated to the turnkey system. Future developments are discussed.

Park, Brian Vandellyn↗
NASA NTRS1997

Nineteenth Space Simulation Conference Cost Effective Testing for the 21st Century

The Nineteenth Space Simulation Conference was hosted by the Institute of Environmental Sciences (IES) and was supported by the American Institute of Aeronautics and Astronautics (AIAA), the American Society for Testing and Materials (ASTM), the National Aeronautics and Space Administration (NASA), and the Canadian Space Agency (CSA). These proceedings attest to the scope of the conference; papers were presented on topics as diverse as shuttle payload contamination effects, simulating Martian environment for testing, to state-of-the-art 6-axis hydraulic shaker testing system. A good cross section of the international aerospace community took advantage of the opportunity to get together, to share their experiences, and to participate in the technical sessions. The two invited keynote speakers were Lieutenant General Malcolm O'Neill (USA, Ret.), past Director of BMDO, and Mr. Thomas Coughlin, Space Programs Manager at the Johns Hopkins University Applied Physics Laboratory. Their most informative and thought provoking talks were on cost effective testing approaches in Defense Department programs for the 21st Century and what part testing plays in the faster, better, cheaper approach for the NEAR and APL programs, respectively. The preceding tutorial and the tour of the Garber Facility of the Air and Space Museum rounded out a comprehensive conference contributing to the knowledge base vital to cost effective testing for successful missions into the 21st Century.

Stecher, Joseph L., III↗
NASA NTRS1997

High Resolution X-Ray Explorer (HIREX)

SAO is involved in a study to determine the feasibility of building an orbiting telescope capable of resolving 7 km structure on the Sun. In order to achieve the required imaging the telescope must have a resolution 0.01 arcsec. This fact challenges the state of the art of orbiting telescopes in several areas: Mirror Figuring; Optical Metrology; Optical Mounting; Mirror Figure Control; System Alignment; Optical Stability; Observatory Pointing; and Image Stability. The telescope design concept is based on a 0.6 m Gregorian-style telescope with a 240 meter effective focal length. This is achieved with 2 mirrors supported at opposite ends of a 35 m space-deployable boom. The telescope mirrors are coated with multilayers designed to reflect a broad XUV passband. A third, small mirror, near the focal plane performs the function of selecting the narrow band that is finally imaged. Image stabilization to the 0.005 arcsec level is achieved by active control of the secondary mirror. The primary mirror is held unadjustably to the spacecraft, its pointing set by the spacecraft orientation. The secondary mirror is mounted on a 6-axis stage that permits its position to be changed to align the telescope in space. The stage is intended for intermittent adjustment, both because of its speed of travel, and the TBD alignment procedure. The third mirror is called the TXI (Tuneable X-ray Imager). It is mounted on a gimbal that permits it to be tipped over a 60 degree range, selecting between the individual wavelengths in the initial bandpass. It can also rotated completely out of the way to allow the full, broadband EUV flux to strike the focal plane. Finally, the focal plane assembly is designed to rotate on the outer edge of a circle centered on the TXI mirror rotation axis. This permits the focal plane to move to the location that the TXI redirects the light once it has been set to a given wavelength response. The Engineering Study is divided into the following areas: Mirror Fabrication and Metrology; Optical Layout-Trade Study between On-axis and Off-axis; Overall System Design; and Pointing Control/Image Stabilization. The observational goals of the mission are described in the Mission Requirements document. The work is being performed to the requirements called out in the Science Requirements document.

Goulb, Leon↗
NASA NTRS1999

High Resolution X-Ray Explorer (HIREX)

SAO has carried out a study to determine the feasibility of building an orbiting telescope capable of resolving 7 km structure on the Sun. In order to achieve the required imaging the telescope must have a resolution 0.01 arcsec. This fact challenges the state of the art of orbiting telescopes in several areas: mirror figuring; optical metrology; optical mounting; mirror figure control; system alignment; optical stability; observatory pointing; and image stability image stability. The telescope design concept is based on a 0.6m Cassegrain-style telescope with a 240 meter effective focal length. This is achieved with 2 mirrors supported at opposite ends of a 27 m space-deployable boom. The telescope mirrors are coated with multilayers designed to reflect a broad XUV passband. A third, small mirror, near the focal plane performs the function of selecting the narrow band that is finally imaged. Image stabilization to the 0.005 a,rcsec level is achieved by active control of the secondary mirror. The primary mirror is held unadjustably to the spacecraft, its pointing set by the space- craft orientation. The secondary mirror is mounted on a 6-axis stage that permits its position to be changed to align the telescope in space. The stage is intended for intermittent adjustment, both because of its speed of travel, and the TBD alignment procedure. The third mirror is called the TXI (Tuneable X-ray Imager). It is mounted on a gimbal that permits it to be tipped over a 60 degree range, selecting between the individual wavelengths in the initial bandpass. It can also rotated completely out of the way to allow the full, broadband EUV flux to strike the focal plane.

Golub, Leon↗
NASA NTRS2008

Design and Calibration of Custom Flowfield/Rake for the F-15B Propulsion Flight Test Fixture

The Propulsion Flight Test Fixture (PFTF) system at NASA Dryden Flight Research Center (DFRC) provides an innovative and cost effective method of flight testing advanced propulsion concepts and components in a relevant environment using DFRC's F-15B #836. The PFTF attaches to the centerline pylon of the aircraft and Has an integrated 6 axis force balance for flight testing of propulsion experiments The PTFF has undergone two previous flight validation test phases: (1)The Local Mach Investigation (LMT) flights, in which an air data boom was attached to a cylinder with a conical nose cap . This flight test phase quantified the local Mach number and the local flow angle at a single point under the F-155B/PFTF. (2) The Cone Drag Experiment (CDE), in which the cylinder / nosecap assembly was tested in order to validate the PFTF's integral 6-component force balance. The next test phase with the PFTF is the flight test of the channeled centerbody axisymmetric inlet. However, for the flight data from this test to be valid, more information must be gathered concerning the quality of the flow through the aerodynamic interface plane of the inlet. The flow angularity and Mach number must be known at multiple locations on the interface plane. Flight data will be gathered using a custom-design flowfield rake to probe the flow underneath the F-15B at the design flight conditions.

Flynn, Darin C.↗
NASA NTRS2004

Aligning Arrays of Lenses and Single-Mode Optical Fibers

A procedure now under development is intended to enable the precise alignment of sheet arrays of microscopic lenses with the end faces of a coherent bundle of as many as 1,000 single-mode optical fibers packed closely in a regular array (see Figure 1). In the original application that prompted this development, the precise assembly of lenses and optical fibers serves as a single-mode spatial filter for a visible-light nulling interferometer. The precision of alignment must be sufficient to limit any remaining wavefront error to a root-mean-square value of less than 1/10 of a wavelength of light. This wavefront-error limit translates to requirements to (1) ensure uniformity of both the lens and fiber arrays, (2) ensure that the lateral distance from the central axis of each lens and the corresponding optical fiber is no more than a fraction of a micron, (3) angularly align the lens-sheet planes and the fiber-bundle end faces to within a few arc seconds, and (4) axially align the lenses and the fiber-bundle end faces to within tens of microns of the focal distance. Figure 2 depicts the apparatus used in the alignment procedure. The beam of light from a Zygo (or equivalent) interferometer is first compressed by a ratio of 20:1 so that upon its return to the interferometer, the beam will be magnified enough to enable measurement of wavefront quality. The apparatus includes relay lenses that enable imaging of the arrays of microscopic lenses in a charge-coupled-device (CCD) camera that is part of the interferometer. One of the arrays of microscopic lenses is mounted on a 6-axis stage, in proximity to the front face of the bundle of optical fibers. The bundle is mounted on a separate stage. A mirror is attached to the back face of the bundle of optical fibers for retroreflection of light. When a microscopic lens and a fiber are aligned with each other, the affected portion of the light is reflected back by the mirror, recollimated by the microscopic lens, transmitted through the relay lenses and the beam compressor/expander, then split so that half goes to a detector and half to the interferometer. The output of the detector is used as a feedback control signal for the six-axis stage to effect alignment.

Liu, Duncan↗
NASA NTRS2009

Technology Innovation of Power Transmission Gearing in Aviation

An overview of rotary wing evolution and innovations over the last 20 years was presented. This overview is provided from a drive system perspective. Examples of technology innovations that have changed and advanced drive systems of rotary wing vehicles will be provided. These innovations include full 6-axis CNC gear manufacture, face gear development to aerospace standards, health and usage monitoring, and gear geometry and bearing improvements. Also, an overview of current state-of-the-art activities being conducted at NASA Glenn is presented with a short look to fixed and rotary wing aircraft and systems needed for the future.

Handschuh, Robert F.↗