Robotic-Movement Payload Lifter and Manipulator

A payload lifter/manipulator module includes a rotatable joint supporting spreader arms angularly spaced with respect to one another. A rigid arm is fixedly coupled to the joint and extends out therefrom to a tip. A tension arm has a first end and a second end with the first end being fixedly coupled to the tip of the rigid arm. The tension arm incorporates pivots along the length thereof. Each pivot can be engaged by or disengaged from the outboard end of a spreader arm based on a position of the spreader arm. A hoist, positioned remotely with respect to the module and coupled to the second end of the tension arm, controls the position of the spreader arms to thereby control the position of the rigid arm's tip. Payload lifter/manipulator assemblies can be constructed with one or more of the modules

Application of a Novel Long-Reach Manipulator Concept to Asteroid Redirect Missions

A high priority mission currently being formulated by NASA is to capture all or part of an asteroid and return it to cis-lunar space for examination by an astronaut crew. Two major mission architectures are currently being considered: in the first (Mission Concept A), a spacecraft would rendezvous and capture an entire free flying asteroid (up to 14 meters in diameter), and in the second (Mission Concept B), a spacecraft would rendezvous with a large asteroid (which could include one of the Martian moons) and retrieve a boulder (up to 4 meters in diameter). A critical element of the mission is the system that will capture the asteroid or boulder material, enclose it and secure it for the return flight. This paper describes the design concepts, concept of operations, structural sizing and masses of capture systems that are based on a new and novel Tendon- Actuated Lightweight In-Space MANipulator (TALISMAN) general-purpose robotic system. Features of the TALISMAN system are described and the status of its technology development is summarized. TALISMAN-based asteroid material retrieval system concepts and concepts-of-operations are defined for each asteroid mission architecture. The TALISMAN-based capture systems are shown to dramatically increase operational versatility while reducing mission risk. Total masses of TALISMAN-based systems are presented, reinforcing the mission viability of using a manipulator-based approach for the asteroid redirect mission

Design and Field Test of a Mass Efficient Crane for Lunar Payload Handling and Inspection: The Lunar Surface Manipulation System

Devices for lifting, translating and precisely placing payloads are critical for efficient Earthbased construction operations. Both recent and past studies have demonstrated that devices with similar functionality will be needed to support lunar outpost operations. Lunar payloads include: a) prepackaged hardware and supplies which must be unloaded from landers and then accurately located at their operational site, b) sensor packages used for periodic inspection of landers, habitat surfaces, etc., and c) local materials such as regolith which require grading, excavation and placement. Although several designs have been developed for Earth based applications, these devices lack unique design characteristics necessary for transport to and use on the harsh lunar surface. These design characteristics include: a) composite components, b) compact packaging for launch, c) simple in-field reconfiguration and repair, and d) support for tele-operated or automated operations. Also, in contrast to Earth-based construction, where special purpose devices dominate a construction site, a lunar outpost will require versatile devices which provide operational benefit from initial construction through sustained operations. This paper will detail the design of a unique, high performance, versatile lifting device designed for operations on the lunar surface. The device is called the Lunar Surface Manipulation System to highlight the versatile nature of the device which supports conventional cable suspended crane operations as well as operations usually associated with a manipulator such as precise positioning where the payload is rigidly grappled by a tool attached to the tip of the device. A first generation test-bed to verify design methods and operational procedures is under development at the NASA Langley Research Center and recently completed field tests at Moses Lake Washington. The design relied on non-linear finite element analysis which is shown to correlate favorably with laboratory experiments. A key design objective, reviewed in this paper, is the device s simplicity, resulting from a focus on the minimum set of functions necessary to perform payload offload. Further development of the device has the potential for significant mass savings, with a high performance device incorporating composite elements estimated to have a mass less than 3% of the mass of the maximum lunar payload lifted at the tip. The paper will conclude with future plans for expanding the operational versatility of the device

A Modular, Reusable Latch and Decking System for Securing Payloads During Launch and Planetary Surface Transport

Efficient handling of payloads destined for a planetary surface, such as the moon or Mars, requires robust systems to secure the payloads during transport on the ground, in-space and on the planetary surface. In addition, mechanisms to release the payloads need to be reliable to ensure successful transfer from one vehicle to another. An efficient payload handling strategy must also consider the devices available to support payload handling. Cranes used for overhead lifting are common to all phases of payload handling on Earth. Similarly, both recent and past studies have demonstrated that devices with comparable functionality will be needed to support lunar outpost operations. A first generation test-bed of a new high performance device that provides the capabilities of both a crane and a robotic manipulator, the Lunar Surface Manipulation System (LSMS), has been designed, built and field tested and is available for use in evaluating a system to secure payloads to transportation vehicles. National Institute of Aerospace, Hampton Va 23662 A payload handling approach must address all phases of payload management including: ground transportation, launch, planetary transfer and installation in the final system. In addition, storage may be required during any phase of operations. Each of these phases requires the payload to be lifted and secured to a vehicle, transported, released and lifted in preparation for the next transportation or storage phase. A critical component of a successful payload handling approach is a latch and associated carrier system. The latch and carrier system should minimize requirements on the: payload, carrier support structure and payload handling devices as well as be able to accommodate a wide range of payload sizes. In addition, the latch should; be small and lightweight, support a method to apply preload, be reusable, integrate into a minimal set of hard-points and have manual interfaces to actuate the latch should a problem occur. A latching system which meets these requirements has been designed and fabricated and will be described in detail. This latching system works in conjunction with a payload handling device such as the LSMS, and the LSMS has been used to test first generation latch and carrier hardware. All tests have been successful during the first phase of operational evaluations. Plans for future tests of first generation latch and carrier hardware with the LSMS are also described

A Versatile Lifting Device for Lunar Surface Payload Handling, Inspection and Regolith Transport Operations

Devices for lifting and transporting payloads and material are critical for efficient Earth-based construction operations. Devices with similar functionality will be needed to support lunar-outpost construction, servicing, inspection, regolith excavation, grading and payload placement. Past studies have proposed that only a few carefully selected devices are required for a lunar outpost. One particular set of operations involves lifting and manipulating payloads in the 100 kg to 3,000 kg range, which are too large or massive to be handled by unassisted astronauts. This paper will review historical devices used for payload handling in space and on earth to derive a set of desirable features for a device that can be used on planetary surfaces. Next, an innovative concept for a lifting device is introduced, which includes many of the desirable features. The versatility of the device is discussed, including its application to lander unloading, servicing, inspection, regolith excavation and site preparation. Approximate rules, which can be used to size the device for specific payload mass and reach requirements, are provided. Finally, details of a test-bed implementation of the innovative concept, which will be used to validate the structural design and develop operational procedures, is provided

Developments to Increase the Performance, Operational Versatility and Automation of a Lunar Surface Manipulation System

The objective of this paper is to describe and summarize the results of the development efforts for the Lunar Surface Manipulation System (LSMS) with respect to increasing the performance, operational versatility, and automation. Three primary areas of development are covered, including; the expansion of the operational envelope and versatility of the current LSMS test-bed, the design of a second generation LSMS, and the development of automation and remote control capability. The first generation LSMS, which has been designed, built, and tested both in lab and field settings, is shown to have increased range of motion and operational versatility. Features such as fork lift mode, side grappling of payloads, digging and positioning of lunar regolith, and a variety of special end effectors are described. LSMS operational viability depends on bei nagble to reposition its base from an initial position on the lander to a mobility chassis or fixed locations around the lunar outpost. Preliminary concepts are presented for the second generation LSMS design, which will perform this self-offload capability. Incorporating design improvements, the second generation will have longer reach and three times the payload capability, yet it will have approximately equivalent mass to the first generation. Lastly, this paper covers improvements being made to the control system of the LSMS test-bed, which is currently operated using joint velocity control with visual cues. These improvements include joint angle sensors, inverse kinematics, and automated controls

Hinge for Use in a Tension Stiffened and Tendon Actuated Manipulator

A tension stiffened and tendon actuated manipulator is provided performing robotic-like movements when acquiring a payload. The manipulator design can be adapted for use in-space, lunar or other planetary installations as it is readily configurable for acquiring and precisely manipulating a payload in both a zero-g environment and in an environment with a gravity field. The manipulator includes a plurality of link arms, a hinge connecting adjacent link arms together to allow the adjacent link arms to rotate relative to each other and a cable actuation and tensioning system provided between adjacent link arms. The cable actuation and tensioning system includes a spreader arm and a plurality of driven and non-driven elements attached to the link arms and the spreader arm. At least one cable is routed around the driven and non-driven elements for actuating the hinge

Improvements to the Tendon-Actuated Lightweight In-Space MANipulator (TALISMAN)

Devices for manipulating and precisely placing payloads are critical for efficient space operations including berthing of spacecraft, in-space assembly, construction and repair. Key to the success of many NASA space activities has been the availability of long-reach crane-like devices such as the Shuttle Remote Manipulation System (SRMS) and the Space Station Remote Manipulation System (SSRMS). These devices have been used for many operations including berthing visiting spacecraft to the International Space Station, deployment of spacecraft, space station assembly, astronaut positioning, payload transfer, and spacecraft inspection prior to atmospheric re-entry. Retiring the Space Transportation System has led to the removal of the SRMS from consideration for in-space missions, thus creating a capability gap. Recognizing this gap, work was initiated at NASA on a new architecture for long-reach space manipulators. Most current devices are constructed by joining revolute joints with carbon composite tubes, with the joints accounting for the majority of the device mass. For example in the case of the SRMS, the entire device mass is 410 kg (904 lbm); the joint structure, motors, gear train, cabling, etc., accounts for the majority of the system mass because the carbon composite tubes mass is 46 kg (101 lbm). An alternate space manipulator concept, the Tendon-Actuated Lightweight In-Space MANipulator (TALISMAN) was created to address deficiencies in the current state-of-the-art in long-reach manipulators. The antagonistic tendon actuated joint architecture allows the motors actuating the joint to be removed from the joint axis, which simplifies the joint design while simultaneously providing mechanical advantage for the motors. The improved mechanical advantage, in turn, reduces the size and power requirements for the motor and gear train. This paper will describe recent architectural improvements to the TALISMAN design that: 1) improve the operational robustness of the system by enabling maneuvers not originally possible by varying the TALISMAN geometry; 2) enable efficient active antagonistic control of a joint while sharing cable between antagonistic tension networks; and 3) uses a unique arrangement of differential capstans to reduce motor torque requirements by an order of magnitude. The paper will also summarize recent efforts to enable autonomous deployment of a TALISMAN including the deployment concept of operations and associated hardware system design. The deployment forces are provided by the same motor systems that are used for articulation, thus reducing the mass associated with the deployment system. The deployment approach is being tested on a TALISMAN prototype which is designed to provide the same operational performance as a shuttle-class manipulator. The prototype has been fabricated and is operational in a new facility at NASA Langley Research Center that has a large area (15.2 m by 21.3 m [50 ft by 70 ft]) air-bearing floor

Recent Developments in the Design, Capabilities and Autonomous Operations of a Lightweight Surface Manipulation System and Test-bed

The first generation of a versatile high performance device for performing payload handling and assembly operations on planetary surfaces, the Lightweight Surface Manipulation System (LSMS), has been designed and built. Over the course of its development, conventional crane type payload handling configurations and operations have been successfully demonstrated and the range of motion, types of operations and the versatility greatly expanded. This enhanced set of 1st generation LSMS hardware is now serving as a laboratory test-bed allowing the continuing development of end effectors, operational techniques and remotely controlled and automated operations. This paper describes the most recent LSMS and test-bed development activities, that have focused on two major efforts. The first effort was to complete a preliminary design of the 2nd generation LSMS that has the capability for limited mobility and can reposition itself between lander decks, mobility chassis, and fixed base locations. A major portion of this effort involved conducting a study to establish the feasibility of, and define, the specifications for a lightweight cable-drive waist joint. The second effort was to continue expanding the versatility and autonomy of large planetary surface manipulators using the 1st generation LSMS as a test-bed. This has been accomplished by increasing manipulator capabilities and efficiencies through both design changes and tool and end effector development. A software development effort has expanded the operational capabilities of the LSMS test-bed to include; autonomous operations based on stored paths, use of a vision system for target acquisition and tracking, and remote command and control over a communications bridge

Commercial Application of In-Space Assembly

In-Space assembly (ISA) expands the opportunities for cost effective emplacement of systems in space. Currently, spacecraft are launched into space and deploy into their operational configuration through a carefully choreographed sequence of operations. The deployment operation dictates the arrangement of the primary systems on the spacecraft, limiting the ability to take full advantage of launch vehicles volume and mass capability. ISA enables vastly different spacecraft architectures and emplacement scenarios to be achieved, including optimal launch configurations ranging from single launch and assembly to on-orbit aggregation of multiple launches at different orbital locations and times. The spacecraft can be visited at different orbital locations and times to effect expansion and maintenance of an operational capability. To date, the primary application of ISA has been in large programs funded by government organizations, such as the International Space Station. Recently, Space Systems Loral (SSL) led a study funded by the Defense Advanced Research Projects Agency (DARPA), called Dragonfly, to investigate the commercial applicability and economic advantages of ISA. In the study, it was shown that ISA enables SSL to double the capability of a commercial satellite system by taking advantage of alternate packaging approaches for the reflectors. The study included an ultra-light-weight robotic system, derived from Mars manipulator designs, to complete assembly of portions of the antenna system using a tool derived from DARPA orbital express and National Aeronautics and Space Administration (NASA) automated structural assembly experience. The mechanical connector that enables robotic ISA takes advantage of decades of development by NASA from the 1970's to 1980's during the Space Station Freedom program, the precursor to the ISS. The mechanical connector was originally designed for rapid astronaut assembly while also providing a high quality structural connection with linear load deflection response. The paper will discuss the business case for ISA, the general approach taken to exploit on-orbit assembly in the GEO communication satellite market, and the concept of operations associated with the ISA approach, thus laying the foundation for ISA to become an accepted operational approach for commercial in-space operations