Design of a welded joint for robotic, on-orbit assembly of space trusses

In the future, some spacecraft will be so large that they must be assembled on-orbit. These spacecraft will be used for such tasks as manned missions to Mars or used as orbiting platforms for monitoring the Earth or observing the universe. Some large spacecraft will probably consist of planar truss structures to which will be attached special purpose, self-contained modules. The modules will most likely be taken to orbit fully outfitted and ready for use in heavy-lift launch vehicles. The truss members will also similarly be taken to orbit, but most unassembled. The truss structures will need to be assembled robotically because of the high costs and risks of extra-vehicular activities. Some missions will involve very large loads. To date, very few structures of any kind have been constructed in space. Two relatively simple trusses were assembled in the Space Shuttle bay in late 1985. Here the development of a design of a welded joint for on-orbit, robotic truss assembly is described. Mechanical joints for this application have been considered previously. Welded joints have the advantage of allowing the truss members to carry fluids for active cooling or other purposes. In addition, welded joints can be made more efficient structurally than mechanical joints. Also, welded joints require little maintenance (will not shake loose), and have no slop which would cause the structure to shudder under load reversal. The disadvantages of welded joints are that a more sophisticated assembly robot is required, weld flaws may be difficult to detect on-orbit, the welding process is hazardous, and welding introduces contamination to the environment. In addition, welded joints provide less structural damping than do mechanical joints. Welding on-orbit was first investigated aboard a Soyuz-6 mission in 1969 and then during a Skylab electron beam welding experiment in 1973. A hand held electron beam welding apparatus is currently being prepared for use on the MIR space station. Presently, Marshall Space Flight Center is evaluating processes appropriate for on-orbit welding. A low gravity environment has been found to have very minor effects on the welding processes appropriate for this application. This is based on tests run on-orbit as well as low gravity environments achieved by flying aircraft in parabolic trajectories. It appears that a modified form of gas tungsten arc welding (GTAW) will be most appropriate for welding together structures on-oribt. The process has been modified to work in a vacuum by providing gas to the arc zone by means of a hollow tungsten electrode with special shielding. A commercial tube welding head has been successfully modified for use on-orbit with a gas leakage rate of approximately 2.5 liters/min. To develop as realistic a joint as possible, a specific truss structure was selected on which to base the design. The structure considered was based on the 120 foot diameter aerobrake tetrahedral truss structure. The truss members were assumed to consist of graphite/epoxy tubes. Also, it was assumed that the nodes were constructed of 2219-T87 aluminum alloy. The magnitude of the member load assumed for design purposes was 100 kips

Design of a welded joint for robotic, on-orbit assembly of space trusses

A preliminary design for a weldable truss joint for on-orbit assembly of large space structures is described. The joint was designed for ease of assembly, for structural efficiency, and to allow passage of fluid (for active cooling or other purposes) along the member through the joint. The truss members were assumed to consist of graphite/epoxy tubes to which were bonded 2219-T87 aluminum alloy end fittings for welding on-orbit to truss nodes of the same alloy. A modified form of gas tungsten arc welding was assumed to be the welding process. The joint was designed to withstand the thermal and structural loading associated with a 120-ft diameter tetrahedral truss intended as an aerobrake for a mission to Mars

Automated construction of lightweight, simple, field-erected structures

The feasibility of automation of construction processes which could result in mobile construction robots is examined. The construction of a large photovoltaic power plant with a peak power output of 100 MW is demonstrated. The reasons to automate the construction process, a conventional construction scenario as the reference for evaluation, and a list of potential cost benefits using robots are presented. The technical feasibility of using robots to construct SPS ground stations is addressed

Development of Assembly Robot System for Flexible Belt-Shaped Subject

We develop an assembly robot system for assembling the flexible belt-shaped subject. An image processing method is developed to recognize the belt-shaped subject. This method is able to determine the grasping point and grasping angle for piking up a subject by a multiple hands unit. CAD information is used to determine the grasping point. The multiple hands unit is developed, which is able to grasp all grasping points of a subject at a time. In addition, the image processing method is used to judge whether a subject is fastened accurately at right position or not during the assembly

Robotic and clinical evaluation of upper limb motor performance in patients with Friedreich's Ataxia: an observational study

Background: Friedreich’s ataxia (FRDA) is the most common hereditary autosomal recessive form of ataxia. In this disease there is early manifestation of gait ataxia, and dysmetria of the arms and legs which causes impairment in daily activities that require fine manual dexterity. To date there is no cure for this disease. Some novel therapeutic approaches are ongoing in different steps of clinical trial. Development of sensitive outcome measures is crucial to prove therapeutic effectiveness. The aim of the study was to assess the reliability and sensitivity of quantitative and objective assessment of upper limb performance computed by means of the robotic device and to evaluate the correlation with clinical and functional markers of the disease severity. Methods: Here we assess upper limb performances by means of the InMotion Arm Robot, a robot designed for clinical neurological applications, in a cohort of 14 children and young adults affected by FRDA, matched for age and gender with 18 healthy subjects. We focused on the analysis of kinematics, accuracy, smoothness, and submovements of the upper limb while reaching movements were performed. The robotic evaluation of upper limb performance consisted of planar reaching movements performed with the robotic system. The motors of the robot were turned off, so that the device worked as a measurement tool. The status of the disease was scored using the Scale for the Assessment and Rating of Ataxia (SARA). Relationships between robotic indices and a range of clinical and disease characteristics were examined. Results: All our robotic indices were significantly different between the two cohorts except for two, and were highly and reliably discriminative between healthy and subjects with FRDA. In particular, subjects with FRDA exhibited slower movements as well as loss of accuracy and smoothness, which are typical of the disease. Duration of Movement, Normalized Jerk, and Number of Submovements were the best discriminative indices, as they were directly and easily measurable and correlated with the status of the disease, as measured by SARA. Conclusions: Our results suggest that outcome measures obtained by means of robotic devices can improve the sensitivity of clinical evaluations of patients’ dexterity and can accurately and efficiently quantify changes over time in clinical trials, particularly when functional scales appear to be no longer sensitive

Mechatronics at the University of Twente

This paper describes some of the mechatronics activities at the University of Twente. In 1989, the founding of the Mechatronics Research Center Twente started a cooperation of the departments of Electrical Engineering, Mechanical Engineering, Applied Mathematics and Computer Science. The mechatronics activities get especially attention in projects in the Ph.D. programme and in the `mechatronic designer' program, but Msc. students participate as well. As an illustration of the philosophy behind the work at the University of Twente and of the activities carried out so far, the paper describes two projects of the institute: the MART (Mobile Autonomous Robot Twente) project and the ALASCA (Automated Laser Aided Servo Controlled Assembly) projec

Diagnosing faults in autonomous robot plan execution

A major requirement for an autonomous robot is the capability to diagnose faults during plan execution in an uncertain environment. Many diagnostic researches concentrate only on hardware failures within an autonomous robot. Taking a different approach, the implementation of a Telerobot Diagnostic System that addresses, in addition to the hardware failures, failures caused by unexpected event changes in the environment or failures due to plan errors, is described. One feature of the system is the utilization of task-plan knowledge and context information to deduce fault symptoms. This forward deduction provides valuable information on past activities and the current expectations of a robotic event, both of which can guide the plan-execution inference process. The inference process adopts a model-based technique to recreate the plan-execution process and to confirm fault-source hypotheses. This technique allows the system to diagnose multiple faults due to either unexpected plan failures or hardware errors. This research initiates a major effort to investigate relationships between hardware faults and plan errors, relationships which were not addressed in the past. The results of this research will provide a clear understanding of how to generate a better task planner for an autonomous robot and how to recover the robot from faults in a critical environment