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The assembly inspection, and maintenance requirements of permanent installations in space demand robotic agents that provide a high level of operational flexibility relative to the mass and volume of the robotic system.
This paper describes the vision algorithms used in several tasks, as well as the vision-guided manipulation algorithms developed to mitigate mismatches between the vision system and the limbs used for manipulation. Two system-level tasks will be described, one involving a two meter walk culminating in a bolt-fastening task and one involving a vision-guided alignment ending with the robot mating with a docking station.
The figure shows the LEMUR II - the second generation of the Limbed Excursion Mechanical Utility Robot (LEMUR), which was described in "Six-Legged Experimental Robot" (NPO-20897), NASA Tech Briefs, Vol. 25, No. 12 (December 2001), page 58. The LEMUR II incorporates a number of improvements, including new features, that extend its capabilities beyond those of its predecessor, which is now denoted the LEMUR I. To recapitulate: the LEMUR I was a six-limbed robot for demonstrating robotic capabilities for assembly, maintenance, and inspection. The LEMUR I was designed to be capable of walking autonomously along a truss structure toward a mechanical assembly at a prescribed location and to perform other operations. The LEMUR I was equipped with stereoscopic video cameras and image-data-processing circuitry for navigation and mechanical operations. It was also equipped with a wireless modem, through which it could be commanded remotely. Upon arrival at a mechanical assembly, the LEMUR I would perform simple mechanical operations with one or both of its front limbs. It could also transmit images to a host computer. Each of the six limbs of the LEMUR I was operated independently. Each of the four rear limbs had three degrees of freedom (DOFs), while each of the front two limbs had four DOFs. The front two limbs were designed to hold, operate, and/or be integrated with tools. The LEMUR I included an onboard computer equipped with an assortment of digital control circuits, digital input/output circuits, analog-to-digital converters for input, and digital-to-analog (D/A) converters for output. Feedback from optical encoders in the limb actuators was utilized for closed-loop microcomputer control of the positions and velocities of the actuators. The LEMUR II incorporates the following improvements over the LEMUR I: a) The drive trains for the joints of the LEMUR II are more sophisticated, providing greater torque and accuracy. b) The six limbs are arranged symmetrically about a hexagonal body platform instead of in straight lines along the sides. This symmetrical arrangement is more conducive to omnidirectional movement in a plane. c) The number of degrees of freedom of each of the rear four limbs has been increased by one. Now, every limb has four degrees of freedom: three at the hip (or shoulder, depending on one s perspective) and one at the knee (or elbow, depending on one s perspective). d) Now every limb (instead of only the two front limbs) can perform operations. For this purpose, each limb is tipped with an improved quick-release mechanism for swapping of end-effector tools. e) New end-effector tools have been developed. These include an instrumented rotary driver that accepts all tool bits that have 0.125-in. (3.175-mm)-diameter shanks, a charge-coupled-device video camera, a super bright light-emitting diode for illuminating the work area of the robot, and a generic collet tool that can be quickly and inexpensively modified to accept any cylindrical object up to 0.5 in. (12.7 mm) in diameter. f) The stereoscopic cameras are mounted on a carriage that moves along a circular track, thereby providing for omnidirectional machine vision. g) The control software has been augmented with software that implements innovations reported in two prior NASA Tech Briefs articles: the HIPS algorithm ["Hybrid Image-Plane/Stereo Manipulation" (NPO-30492), Vol. 28, No. 7 (July 2004), page 55] and the CAMPOUT architecture ["An Architecture for Controlling Multiple Robots" (NPO-30345), Vol. 28, No. 10 (October 2004), page 65].
Robonaut 2 (R2) has completed its fixed base activities on-board the ISS and is scheduled to receive its climbing legs in early 2014. In its continuing line of firsts, the R2 torso finished up its on-orbit activities on its stanchion with the manipulation of space blanket materials and performed multiple tasks under teleoperation control by IVA astronauts. The successful completion of these two IVA experiments is a key step in Robonaut's progression towards an EVA capability. Integration with the legs and climbing inside the ISS will provide another important part of the experience that R2 will need prior to performing tasks on the outside of ISS. In support of these on-orbit activities, R2 has been traversing across handrails in simulated zero-g environments and working with EVA tools and equipment on the ground to determine manipulation strategies for an EVA Robonaut. R2 made significant advances in robotic manipulation of deformable materials in space while working with its softgoods task panel. This panel features quarter turn latches that secure a space blanket to the task panel structure. The space blanket covers two cloth cubes that are attached with Velcro to the structure. R2 was able to open and close the latches, pull back the blanket, and remove the cube underneath. R2 simulated cleaning up an EVA worksite as well, by replacing the cube and reattaching the blanket. In order to interact with the softgoods panel, R2 has both autonomously and with a human in the loop identified and localized these deformable objects. Using stereo color cameras, R2 identified characteristic elements on the softgoods panel then extracted the location and orientation of the object in its field of view using stereo disparity and kinematic transforms. R2 used both vision processing and supervisory control to successfully accomplish this important task. Teleoperation is a key capability for Robonaut's effectiveness as an EVA system. To build proficiency, crewmembers have attempted increasingly difficult tasks using R2 inside the Station. After donning motion capture equipment and a virtual reality visor, Expedition 34/35 flight engineer Tom Marshburn began operations with simple hand movements. Having gained confidence, Marshburn guided R2's arms in a leader-follower exercise with crewmate Chris Cassidy. He was also able to use the hand to grab a tumbling roll of tape, a task only demonstrable in microgravity. Later efforts saw Cassidy handle softgoods through shared control with ground operators, mimicking an activity previously achieved using only autonomy. Robotic climbing through the ISS on handrails requires both precision motion and compliant grasps in order to both position grippers on handrails/seat track and prevent large internal forces. R2 climbs using actively controlled compliance and torque limiting to meet both the precision and softness requirements. During a step, the attached leg is controlled to be strong and stiff in order to maintain precision trajectory tracking. The swing leg is controlled to be stiff but weak to minimize unintentional impact forces while maintaining precision. During a simulated dual limb grasp (as shown in Figure 1), the R2 controller maintains one limb rigid and one limb soft to prevent large internal forces from building up. R2's grippers also use a form of force control to limit grip force while not fully closed on either a handrail or seat track thus limiting unintentional forces on cables/objects that may be present in R2's translational path. The on-board torso R2 safety system relies on a single end-effector velocity limit to prevent potential impact forces from exceeding Station maximum load requirements. R2's mobile configuration required modifications to the velocity limiting safety function due to its large, dynamic inertia. R2's legs maneuver the robot's mass creating configuration dependent, joint-relative inertias. A single all-encompassing velocity limit to cover worst case inertia is prohibitively low. The upgraded R2 control and safety systems solve this problem using momentum limiting, momentum control, and kinetic energy minimization. Momentum and kinetic energy take the robot mass into account relieving low velocity restrictions on low inertia end-effectors while ensuring that the overall mass of R2 is limited from hazardous velocities. The momentum of R2's five safety nodes (each of the four end-effectors and the body) is monitored and compared to a single momentum limit. If any of the five nodes exceeds the safety limit, the motor power is removed and the robot comes to a stop. Momentum control/limiting also provides a simple, reliable method to integrate hand held tools into the safety system by providing the tool mass to the control system thus automatically reducing the allowable velocity of the end-effector with the tool. Work on the ground continues to build the skill set for an EVA Robonaut. Recent experiments (Figure 2) demonstrate how a teleoperator can use R2 to manipulate a tether hook, an important safety precaution on spacewalks. Another task displayed Robonaut's ability to pull back a protective jacket over a hose and search for damage, as well as inspect a quick-disconnect fitting for debris. Demonstrations such as these are indicative of EVA work done on ISS, specifically seen during a series of spacewalks over 2012 and 2013 where astronauts searched for an ammonia leak in one of the external cooling loops. Through experiments both on ISS and on the ground, R2 is evolving and providing the information needed to plan out the upgrades that will make an EVA Robonaut an effective tool. With the addition of legs, R2 will start climbing inside the space station and supply invaluable information on how the climbing strategies and task stabilization techniques must be refined. Ground R2 systems will continue to work with additional EVA tools and equipment in preparation for onboard IVA testing and future EVA applications.
Inspired by the light scattering and focusing properties of distributed optical assemblies in Nature, such as rainbows and aerosols, and by recent laboratory successes in optical trapping and manipulation, we propose a unique combination of space optics and autonomous robotic system technology, to enable a new vision of space system architecture with applications to ultra-lightweight space optics and, ultimately, in-situ space system fabrication. Typically, the cost of an optical system is driven by the size and mass of the primary aperture. The ideal system is a cloud of spatially disordered dust-like objects that can be optically manipulated: it is highly reconfigurable, fault-tolerant, and allows very large aperture sizes at low cost. This new concept is based on recent understandings in the physics of optical manipulation of small particles in the laboratory and the engineering of distributed ensembles of spacecraft swarms to shape an orbiting cloud of micron-sized objects. In the same way that optical tweezers have revolutionized micro- and nano-manipulation of objects, our breakthrough concept will enable new large scale NASA mission applications and develop new technology in the areas of Astrophysical Imaging Systems and Remote Sensing because the cloud can operate as an adaptive optical imaging sensor. While achieving the feasibility of constructing one single aperture out of the cloud is the main topic of this work, it is clear that multiple orbiting aerosol lenses could also combine their power to synthesize a much larger aperture in space to enable challenging goals such as exo-planet detection. Furthermore, this effort could establish feasibility of key issues related to material properties, remote manipulation, and autonomy characteristics of cloud in orbit. There are several types of endeavors (science missions) that could be enabled by this type of approach, i.e. it can enable new astrophysical imaging systems, exo-planet search, large apertures allow for unprecedented high resolution to discern continents and important features of other planets, hyperspectral imaging, adaptive systems, spectroscopy imaging through limb, and stable optical systems from Lagrange-points. Furthermore, future micro-miniaturization might hold promise of a further extension of our dust aperture concept to other more exciting smart dust concepts with other associated capabilities. Our objective in Phase II was to experimentally and numerically investigate how to optically manipulate and maintain the shape of an orbiting cloud of dust-like matter so that it can function as an adaptable ultra-lightweight surface. Our solution is based on the aperture being an engineered granular medium, instead of a conventional monolithic aperture. This allows building of apertures at a reduced cost, enables extremely fault-tolerant apertures that cannot otherwise be made, and directly enables classes of missions for exoplanet detection based on Fourier spectroscopy with tight angular resolution and innovative radar systems for remote sensing. In this task, we have examined the advanced feasibility of a crosscutting concept that contributes new technological approaches for space imaging systems, autonomous systems, and space applications of optical manipulation. The proposed investigation has matured the concept that we started in Phase I to TRL 3, identifying technology gaps and candidate system architectures for the space-borne cloud as an aperture.
Our objective is to investigate the conditions to manipulate and maintain the shape of an orbiting cloud of dust-like matter so that it can function as an ultra-lightweight surface with useful and adaptable electromagnetic characteristics, for instance, in the optical, RF, or microwave bands. Inspired by the light scattering and focusing properties of distributed optical assemblies in Nature, such as rainbows and aerosols, and by recent laboratory successes in optical trapping and manipulation, we propose a unique combination of space optics and autonomous robotic system technology, to enable a new vision of space system architecture with applications to ultra-lightweight space optics and, ultimately, in-situ space system fabrication. Typically, the cost of an optical system is driven by the size and mass of the primary aperture. The ideal system is a cloud of spatially disordered dust-like objects that can be optically manipulated: it is highly reconfigurable, fault-tolerant, and allows very large aperture sizes at low cost. See Figure 1 for a scenario of application of this concept. The solution that we propose is to construct an optical system in space in which the nonlinear optical properties of a cloud of micron-sized particles are shaped into a specific surface by light pressure, allowing it to form a very large and lightweight aperture of an optical system, hence reducing overall mass and cost. Other potential advantages offered by the cloud properties as optical system involve possible combination of properties (combined transmit/receive), variable focal length, combined refractive and reflective lens designs, and hyper-spectral imaging. A cloud of highly reflective particles of micron-size acting coherently in a specific electromagnetic band, just like an aerosol in suspension in the atmosphere, would reflect the Sun's light much like a rainbow. The only difference with an atmospheric or industrial aerosol is the absence of the supporting fluid medium. This new concept is based on recent understandings in the physics of optical manipulation of small particles in the laboratory and the engineering of distributed ensembles of spacecraft clouds to shape an orbiting cloud of micron-sized objects. In the same way that optical tweezers have revolutionized micro- and nano-manipulation of objects, our breakthrough concept will enable new large scale NASA mission applications and develop new technology in the areas of Astrophysical Imaging Systems and Remote Sensing because the cloud can operate as an adaptive optical imaging sensor. While achieving the feasibility of constructing one single aperture out of the cloud is the main topic of this work, it is clear that multiple orbiting aerosol lenses could also combine their power to synthesize a much larger aperture in space to enable challenging goals such as exoplanet detection. Furthermore, this effort could establish feasibility of key issues related to material properties, remote manipulation, and autonomy characteristics of cloud in orbit. There are several types of endeavors (science missions) that could be enabled by this type of approach, i.e. it can enable new astrophysical imaging systems, exoplanet search, large apertures allow for unprecedented high resolution to discern continents and important features of other planets, hyperspectral imaging, adaptive systems, spectroscopy imaging through limb, and stable optical systems from Lagrange-points. Future micro-miniaturization might hold promise of a further extension of our dust aperture concept to other more exciting smart dust concepts with other associated capabilities.