Ground Robotic Hand Applications for the Space Program study (GRASP)

This document reports on a NASA-STDP effort to address research interests of the NASA Kennedy Space Center (KSC) through a study entitled, Ground Robotic-Hand Applications for the Space Program (GRASP). The primary objective of the GRASP study was to identify beneficial applications of specialized end-effectors and robotic hand devices for automating any ground operations which are performed at the Kennedy Space Center. Thus, operations for expendable vehicles, the Space Shuttle and its components, and all payloads were included in the study. Typical benefits of automating operations, or augmenting human operators performing physical tasks, include: reduced costs; enhanced safety and reliability; and reduced processing turnaround time

The Development of a Sensitive Manipulation Platform

This thesis presents an extension of sensitive manipulation which transforms tactile sensors away from end effectors and closer to whole body sensory feedback. Sensitive manipulation is a robotics concept which more closely replicates nature by employing tactile sensing to interact with the world. While traditional robotic arms are specifically designed to avoid contact, biological systems actually embrace and intentionally contact the environment. This arm is inspired by these biological systems and therefore has compliant joints and a tactile shell surrounding the two primary links of the arm. The manipulator has also been designed to be capable of both industrial and humanoid style manipulation. There are an untold number of applications for an arm with increased tactile feedback primarily in dynamic environments such as in industrial, humanoid, and prosthetic applications. The arm developed for this thesis is intended to be a desktop research platform, however, one of the most influential applications for increased tactile feedback is in prosthetics which are operate in ever changing and contact ridden environments while continuously interacting with humans. This thesis details the simulation, design, analysis, and evaluation of a the first four degrees of freedom of a robotic arm with particular attention given to the design of modular series elastic actuators in each joint as well as the incorporation of a shell of tactile sensors

Optimization for Commercialization of A Two Degree of Freedom Powered Arm Orthosis

In the United States, more than 18 million people suffer from upper extremity injury. This population is in need of a device both to aid in the completion of activities of daily living (eating and grooming), as well as to provide daily muscular therapy. To assist persons suffering from disabling upper extremity neuromuscular diseases, this thesis concerned the redesign of a powered arm brace from a proof-of-concept design to a more functional, marketable product. The principles of Design for Manufacturability and Assembly (DFMA) were employed as part of the design methodology to create a product that could be scaled into production. Additionally, numerical analyses including Finite Element Analysis (FEA) were completed to prove the both the safety and structural integrity of the orthosis in computer simulations. The design was then successfully tested with marked improvement over the previous design, including a 58% reduction in weight, decreased manufacturing costs, and a significant improvement in functionality and comfort

Electromechanical System Integration for a Powered Upper Extremity Orthosis

Wearable robotics for assistance and rehabilitation are not yet considered commercially mainstream products, and as a result have not yet seen advanced controls systems and interfaces. Consequently, the available technology is mostly adapted from systems used in parallel technologies, rather than custom applications intended for human use. This study concerns itself with the design and development of a custom control system for a 2-degree of freedom powered upper extremity orthosis capable of driving elbow flexion/extension 135º and humeral rotation 95º . The orthosis has been evaluated for use as both a long-term assistive technology device for persons with disabilities, and as a short-term rehabilitative tool for persons recovering injury. The target demographics for such a device vary in age, cognitive ability and physical function, thus requiring several input parameters requiring consideration. This study includes a full evaluation of the potential users of the device, as well as parameter considerations that are required during the design phase. The final control system is capable of driving each DOF independently or simultaneously, for a more realistic and natural coupled-motion, with proportional control by pulse-width modulation. The dual-axis joystick interface wirelessly transmits to the 1.21 pound control pack which houses a custom microcontroller-driven PCB and 1800 milliamp-hour lithium-ion rechargeable battery capable of delivering 4 hours of running time. Upon integration with the 2 DOF orthosis device, a user may complete full range of motion with up to 5 pounds in their hand in less than 7 seconds, providing full functionality to complete acts of daily living, thus improving quality of life

Design and Prototyping of a 3DOF Worm-drive Robot Arm

PEARLDOI for this publication Labels There are no labels on this output. Add labels Many designs for robot arms exist. Here we present an affordable revolute arm, capable of executing simple pick-and-place tasks. The arm employs a double parallelogram structure, which ensures its endpoint angle in the plane of the upper arm remains fixed without the need for additional actuation. Its limbs are fabricated from circular tubes made from bonded carbon fiber, to ensure low moving mass while maintaining high rigidity. All custom structural elements of the arm are produced via 3D printing. We employ worm-drive DC motor actuation to ensure that stationary configurations are maintained without the necessity of continuous motor power. Our discussion encompasses an analysis of the arm’s kinematics. A simulation of the arm’s operation was carried out in MATLAB, revealing key operational metrics. In conclusion, we achieved extrinsic endpoint position tracking by implementing its inverse kinematics and PID control using a microcontroller. We also demonstrate the arm’s functionality through simple movement tracking and object manipulation tasks

SHARC: Space Habitat, Assembly and Repair Center

Integrated Space Systems (ISS) has taken on the task of designing a Space Habitat, Assembly and Repair Center (SHARC) in Low Earth Orbit to meet the future needs of the space program. Our goal is to meet the general requirements given by the 1991/1992 AIAA/LORAL Team Space Design competition with an emphasis on minimizing the costs of such a design. A baseline structural configuration along with preliminary designs of the major subsystems was created. Our initial mission requirements, which were set by AIAA, were that the facility be able to: support simultaneous assembly of three major vehicles; conduct assembly operations and minimal extra vehicular activity (EVA); maintain orbit indefinitely; and assemble components 30 feet long with a 10 foot diameter in a shirtsleeve environment

Additive manufacturing using robotic manipulators, FDM, and aerosol jet printers.

Additive manufacturing has created countless new opportunities for fabrication of devices in the past few years. Advances in additive manufacturing continue to change the way that many devices are fabricated by simplifying processes and often lowering cost. Fused deposition modeling (FDM) is the most common form of 3D printing. It is a well-developed process that can print various plastic materials into three-dimensional structures. This technology is used in a lot of industries for rapid prototyping and sometimes small batch manufacturing. It is very inexpensive, and a prototype can be created in a few hours, rather than days. This is useful for testing dimensions of designs without wasting time and money. Recently, a new form of additive manufacturing was developed known as aerosol jet printing (AJP). This process uses a specially developed ink with a low viscosity to print a wide range of metals and polymers. These printers work by atomizing the ink into a mist that is pushed out of a nozzle into a focused beam. This beam deposits material on the substrate at a standoff distance of 3-5 mm. Since this is a non-contact printing process, many non-planar surfaces can be printed on quite easily. AJP also offers very small feature sizes as low as 30 µm. It is useful for printing conductive traces and printing on unique surfaces. These printed traces often need some form of post processing to fully cure the ink and remove any solvent. For metals such as silver, this post processing removes solvent, increases conductivity, and increases adhesion. Methods for post processing include using an oven, intense pulse light (IPL), or a laser that follows the traces as they are printed. Of these methods, the IPL offers the greatest flexibility because it can cure a larger area than the laser and only takes a few seconds compared to hours in an oven. In this thesis, these two types of additive manufacturing processes, FDM and AJP, are explored, developed, and integrated with robotic manipulators in a custom system called the “Nexus”. By integrating these processes with robotic manipulators, these processes can be automated and combined to create unique processes and streamlined fabrication. The third chapter covers the development of the AJP printing and curing processes and integration with the Nexus system as well as some example devices such as a strain gauge. The fourth chapter goes over how a custom FDM module was integrated into the Nexus system and how material extrusion is synchronized with the motion component. Finally, in the second part of the fourth chapter, an FDM 3D printer is designed and fabricated as an end effector for a 6DOF robotic arm to be used in the Nexus system. To control these processes, G-Code is used to tell the machines the correct path to take. Methods for generating 5-axis G-Code are suggested to enable non-planar printing in the future

A Lower Limb Prosthesis with Active Alignment for Reduced Limb Loading

Over the past decade, the growing field of robotics has created new possibilities in lower limb prostheses. The focus of these new prostheses has been replicating the dynamics of the lost limb in order to restore gait of individuals with lower limb amputations to healthy norms. This places demanding loads on the residual limb. Compensation by the rest of body is high, causes overloading of intact joints and can lead to deterioration of mobility and overall health. Abnormalities remain present in the person’s gait, stemming from the loading of soft tissue and the altered anatomy of the affected limb. In this dissertation, an experimental prosthesis is developed with systematic, simulation based techniques. Kinematics and kinetics of the prosthesis design are altered in order to actively realign the limb in relation to the center of pressure during stance, allowing positive power to be generated by the prosthesis while actively reducing the magnitude of the sagittal moment transferred to the residual limb. Initial findings show that during walking with the experimental device compared to a daily use prosthesis, peak pressures on the residual limb are lowered by over 10% while maintaining walking speed

Microrobots for wafer scale microfactory: design fabrication integration and control.

Future assembly technologies will involve higher automation levels, in order to satisfy increased micro scale or nano scale precision requirements. Traditionally, assembly using a top-down robotic approach has been well-studied and applied to micro-electronics and MEMS industries, but less so in nanotechnology. With the bloom of nanotechnology ever since the 1990s, newly designed products with new materials, coatings and nanoparticles are gradually entering everyone’s life, while the industry has grown into a billion-dollar volume worldwide. Traditionally, nanotechnology products are assembled using bottom-up methods, such as self-assembly, rather than with top-down robotic assembly. This is due to considerations of volume handling of large quantities of components, and the high cost associated to top-down manipulation with the required precision. However, the bottom-up manufacturing methods have certain limitations, such as components need to have pre-define shapes and surface coatings, and the number of assembly components is limited to very few. For example, in the case of self-assembly of nano-cubes with origami design, post-assembly manipulation of cubes in large quantities and cost-efficiency is still challenging. In this thesis, we envision a new paradigm for nano scale assembly, realized with the help of a wafer-scale microfactory containing large numbers of MEMS microrobots. These robots will work together to enhance the throughput of the factory, while their cost will be reduced when compared to conventional nano positioners. To fulfill the microfactory vision, numerous challenges related to design, power, control and nanoscale task completion by these microrobots must be overcome. In this work, we study three types of microrobots for the microfactory: a world’s first laser-driven micrometer-size locomotor called ChevBot，a stationary millimeter-size robotic arm, called Solid Articulated Four Axes Microrobot (sAFAM), and a light-powered centimeter-size crawler microrobot called SolarPede. The ChevBot can perform autonomous navigation and positioning on a dry surface with the guidance of a laser beam. The sAFAM has been designed to perform nano positioning in four degrees of freedom, and nanoscale tasks such as indentation, and manipulation. And the SolarPede serves as a mobile workspace or transporter in the microfactory environment