Machinery, equipment and tools: A compilation

A selection of new hand tools, modifications of existing tools, and techniques developed in the course of NASA research and development project is presented. The items are presented in two sections: Power Hand Tools and Accessories, and Manual Hand Tools and Accessories

Frontiers in Ultra-Precision Machining

Ultra-precision machining is a multi-disciplinary research area that is an important branch of manufacturing technology. It targets achieving ultra-precision form or surface roughness accuracy, forming the backbone and support of today’s innovative technology industries in aerospace, semiconductors, optics, telecommunications, energy, etc. The increasing demand for components with ultra-precision accuracy has stimulated the development of ultra-precision machining technology in recent decades. Accordingly, this Special Issue includes reviews and regular research papers on the frontiers of ultra-precision machining and will serve as a platform for the communication of the latest development and innovations of ultra-precision machining technologies

A family of BAPTAs for GEO and LEO applications

The application of a Bearing and Power Transfer Assembly (BAPTA) to a Solar Array Drive for communications satellites is presented. The basic principles which were used as guidelines for design and development are developed and the three main subassemblies are described in detail. The results of vibration qualification and thermal vacuum life tests are included

Thin glass shells for active optics for future space telescopes

We present a method for the manufacturing of thin shells of glass, which appears promising for the development of active optics for future space telescopes. The method exploits the synergy of different mature technologies, while leveraging the commercial availability of large, high-quality sheets of glass, with thickness up to few millimeters. The first step of the method foresees the pre-shaping of flat substrates of glass by replicating the accurate shape of a mold via hot slumping technology. The replication concept is advantageous for making large optics composed of many identical or similar segments. After the hot slumping, the shape error residual on the optical surface is addressed by applying a deterministic sub-aperture technology as computer-controlled bonnet polishing and/or ion beam figuring. Here we focus on the bonnet polishing case, during which the thin, deformable substrate of glass is temporary stiffened by a removable holder. In this paper, we report on the results so far achieved on a 130 mm glass shell case study.Comment: This is a pre-print of an article published in CEAS Space Journal. The final authenticated version is available online at: http://link.springer.com/article/10.1007/s12567-019-00259-

The Apache Point Observatory Galactic Evolution Experiment (APOGEE) Spectrographs

We describe the design and performance of the near-infrared (1.51--1.70 micron), fiber-fed, multi-object (300 fibers), high resolution (R = lambda/delta lambda ~ 22,500) spectrograph built for the Apache Point Observatory Galactic Evolution Experiment (APOGEE). APOGEE is a survey of ~ 10^5 red giant stars that systematically sampled all Milky Way populations (bulge, disk, and halo) to study the Galaxy's chemical and kinematical history. It was part of the Sloan Digital Sky Survey III (SDSS-III) from 2011 -- 2014 using the 2.5 m Sloan Foundation Telescope at Apache Point Observatory, New Mexico. The APOGEE-2 survey is now using the spectrograph as part of SDSS-IV, as well as a second spectrograph, a close copy of the first, operating at the 2.5 m du Pont Telescope at Las Campanas Observatory in Chile. Although several fiber-fed, multi-object, high resolution spectrographs have been built for visual wavelength spectroscopy, the APOGEE spectrograph is one of the first such instruments built for observations in the near-infrared. The instrument's successful development was enabled by several key innovations, including a "gang connector" to allow simultaneous connections of 300 fibers; hermetically sealed feedthroughs to allow fibers to pass through the cryostat wall continuously; the first cryogenically deployed mosaic volume phase holographic grating; and a large refractive camera that includes mono-crystalline silicon and fused silica elements with diameters as large as ~ 400 mm. This paper contains a comprehensive description of all aspects of the instrument including the fiber system, optics and opto-mechanics, detector arrays, mechanics and cryogenics, instrument control, calibration system, optical performance and stability, lessons learned, and design changes for the second instrument.Comment: 81 pages, 67 figures, PASP, accepte

Importance and applications of robotic and autonomous systems (RAS) in railway maintenance sector: a review

Maintenance, which is critical for safe, reliable, quality, and cost-effective service, plays a dominant role in the railway industry. Therefore, this paper examines the importance and applications of Robotic and Autonomous Systems (RAS) in railway maintenance. More than 70 research publications, which are either in practice or under investigation describing RAS developments in the railway maintenance, are analysed. It has been found that the majority of RAS developed are for rolling-stock maintenance, followed by railway track maintenance. Further, it has been found that there is growing interest and demand for robotics and autonomous systems in the railway maintenance sector, which is largely due to the increased competition, rapid expansion and ever-increasing expense

Tuning of Parameters for Robotic Contouring Based on the Evaluation of Force Deviation

The application of industrial robots with advanced sensor systems in unstructured environments is continuously becoming wider. A widely used type of advanced sensor systems is the force-torque sensor. Force-torque sensors are typically used for applications such as robot grinding, sanding, polishing, and deburring, where a constant force is exerted upon a workpiece. In this research, control parameters for exerting a constant force along a predefined path are evaluated in laboratory conditions. The experimental setup with the contouring force feedback is composed of a Fanuc LRMate six-degree-of-freedom industrial robot with an integrated force-torque sensor. Control parameters of the Contouring function within the Fanuc robot controller are tuned in four contouring experiments. The experiments conducted in this research are: i) flat beam, ii) flat beam with a rigid support, iii) wave shaped compliant plate, and iv) compliant flat plate. During the experiments, contouring parameters were altered in order to collect the feedback on the values of the force to be used for the evaluation of the force deviation. A fitness function for the evaluation of the force deviation and the tuning of the control parameters is presented. The fitness function enables a selection of initial control parameters which minimize the force deviation during the robot contouring process

Human-Centered Design of a Collaborative Robotic System for the Shoe-Polishing Process

Demand for automated processes in the manufacturing industry is now shifting toward flexible, human-centered systems that combine productivity and high product quality, thus combining the advantages of automated and robotic systems with the high-value-added skills of operators and craftsmen. This trend is even more crucial for small and medium-sized enterprises operating in the “Made in Italy” fashion industry. The paper presents the study, simulation, and preliminary testing of a collaborative robotic system for shoe polishing that can reduce manual labor by limiting it to the finishing stage of the process, where the aesthetic result is fully achieved, with a benefit also in terms of ergonomics for the operator. The influence of process parameters and design solutions are discussed by presenting preliminary test results and providing hints for future developments

human robot collaborative reconfigurable platform for surface finishing processes

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A model-based residual approach for human-robot collaboration during manual polishing operations

A fully robotized polishing of metallic surfaces may be insufficient in case of parts with complex geometric shapes, where a manual intervention is still preferable. Within the EU SYMPLEXITY project, we are considering tasks where manual polishing operations are performed in strict physical Human-Robot Collaboration (HRC) between a robot holding the part and a human operator equipped with an abrasive tool. During the polishing task, the robot should firmly keep the workpiece in a prescribed sequence of poses, by monitoring and resisting to the external forces applied by the operator. However, the user may also wish to change the orientation of the part mounted on the robot, simply by pushing or pulling the robot body and changing thus its configuration. We propose a control algorithm that is able to distinguish the external torques acting at the robot joints in two components, one due to the polishing forces being applied at the end-effector level, the other due to the intentional physical interaction engaged by the human. The latter component is used to reconfigure the manipulator arm and, accordingly, its end-effector orientation. The workpiece position is kept instead fixed, by exploiting the intrinsic redundancy of this subtask. The controller uses a F/T sensor mounted at the robot wrist, together with our recently developed model-based technique (the residual method) that is able to estimate online the joint torques due to contact forces/torques applied at any place along the robot structure. In order to obtain a reliable residual, which is necessary to implement the control algorithm, an accurate robot dynamic model (including also friction effects at the joints and drive gains) needs to be identified first. The complete dynamic identification and the proposed control method for the human-robot collaborative polishing task are illustrated on a 6R UR10 lightweight manipulator mounting an ATI 6D sensor