Range 7 Scanner Integration with PaR Robot Scanning System

An interface bracket and coordinate transformation matrices were designed to allow the Range 7 scanner to be mounted on the PaR Robot detector arm for scanning the heat shield or other object placed in the test cell. A process was designed for using Rapid Form XOR to stitch data from multiple scans together to provide an accurate 3D model of the object scanned. An accurate model was required for the design and verification of an existing heat shield. The large physical size and complex shape of the heat shield does not allow for direct measurement of certain features in relation to other features. Any imaging devices capable of imaging the entire heat shield in its entirety suffers a reduced resolution and cannot image sections that are blocked from view. Prior methods involved tools such as commercial measurement arms, taking images with cameras, then performing manual measurements. These prior methods were tedious and could not provide a 3D model of the object being scanned, and were typically limited to a few tens of measurement points at prominent locations. Integration of the scanner with the robot allows for large complex objects to be scanned at high resolution, and for 3D Computer Aided Design (CAD) models to be generated for verification of items to the original design, and to generate models of previously undocumented items. The main components are the mounting bracket for the scanner to the robot and the coordinate transformation matrices used for stitching the scanner data into a 3D model. The steps involve mounting the interface bracket to the robot's detector arm, mounting the scanner to the bracket, and then scanning sections of the object and recording the location of the tool tip (in this case the center of the scanner's focal point). A novel feature is the ability to stitch images together by coordinates instead of requiring each scan data set to have overlapping identifiable features. This setup allows models of complex objects to be developed even if the object is large and featureless, or has sections that don't have visibility to other parts of the object for use as a reference. In addition, millions of points can be used for creation of an accurate model [i.e. within 0.03 in. (=0.8 mm) over a span of 250 in. (=635 mm)]

Swamp Works- Multiple Projects

My Surface Systems internship over the summer 2013 session covered a broad range of projects that utilized multiple fields of engineering and technology. This internship included a project to create a command center for a 120 ton regolith bin, for the design and assembly of a blast shield to add further protection for the Surface Systems engineers, for the design and assembly of a portable four monitor hyper wall strip that could extend as large as needed, research and programming a nano drill that could be utilized on a next generation robot or rover, and social media tasks including the making of videos, posting to social networking websites and creation of a new outreach program to help spread the word about the Swamp Works laboratory

3D Printed Robotic Hand

Dexterous robotic hands are changing the way robots and humans interact and use common tools. Unfortunately, the complexity of the joints and actuations drive up the manufacturing cost. Some cutting edge and commercially available rapid prototyping machines now have the ability to print multiple materials and even combine these materials in the same job. A 3D model of a robotic hand was designed using Creo Parametric 2.0. Combining "hard" and "soft" materials, the model was printed on the Object Connex350 3D printer with the purpose of resembling as much as possible the human appearance and mobility of a real hand while needing no assembly. After printing the prototype, strings where installed as actuators to test mobility. Based on printing materials, the manufacturing cost of the hand was $167, significantly lower than other robotic hands without the actuators since they have more complex assembly processes

Quick Attach Docking Interface for Lunar Electric Rover

The NASA Lunar Electric Rover (LER) has been developed at Johnson Space Center as a next generation mobility platform. Based upon a twelve wheel omni-directional chassis with active suspension the LER introduces a number of novel capabilities for lunar exploration in both manned and unmanned scenarios. Besides being the primary vehicle for astronauts on the lunar surface, LER will perform tasks such as lunar regolith handling (to include dozing, grading, and excavation), equipment transport, and science operations. In an effort to support these additional tasks a team at the Kennedy Space Center has produced a universal attachment interface for LER known as the Quick Attach. The Quick Attach is a compact system that has been retro-fitted to the rear of the LER giving it the ability to dock and undock on the fly with various implements. The Quick Attach utilizes a two stage docking approach; the first is a mechanical mate which aligns and latches a passive set of hooks on an implement with an actuated cam surface on LER. The mechanical stage is tolerant to misalignment between the implement and the LER during docking and once the implement is captured a preload is applied to ensure a positive lock. The second stage is an umbilical connection which consists of a dust resistant enclosure housing a compliant mechanism that is optionally actuated to mate electrical and fluid connections for suitable implements. The Quick Attach system was designed with the largest foreseen input loads considered including excavation operations and large mass utility attachments. The Quick Attach system was demonstrated at the Desert Research And Technology Studies (D-RA TS) field test in Flagstaff, AZ along with the lightweight dozer blade LANCE. The LANCE blade is the first implement to utilize the Quick Attach interface and demonstrated the tolerance, speed, and strength of the system in a lunar analog environment

Reducing Extra-Terrestrial Excavation Forces with Percussion

High launch costs and mission requirements drive the need for low mass excavators with mobility platforms, which in turn have little traction and excavation reaction capacity in low gravity environments. This presents the need for precursor and long term future missions with low mass robotic mining technology to perform In-Situ Resource Utilization (ISRU) tasks. This paper discusses a series of experiments that investigate the effectiveness of a percussive digging device to reduce excavation loads and thereby the mass of the excavator itself. The goal of percussive excavation is to fluidize dry regolith in front of the leading edge of the tool by mechanically separating the microscopic interlocking grains resulting in a reduced force needed to shear the soil. There are several variables involved with this technique; this experiment varied: Impact energy, frequency, and excavation speed and held constant: impact direction, depth of cut, angle of tool, and soil bulk density. The test apparatus consisted of an aluminum truss bridge with a central pivoting arm. Attached to the arm was a winch with a load cell in line that recorded the tension in the cable and therefore the excavation load. The arm could be adjusted for excavation depth which was recorded along with the arm angle relative to the bridge. A percussive mechanism and 30" wide pivoting bucket were attached at the end of the arm simulating a basic backhoe with a percussion direction tangent to the direction of . movement. Internally the mechanism used a set of die springs and barrel cam to produce the percussive blow. By changing the springs and the speed of the motor the impact energy and frequency of percussion could be varied independently. Impact energies from 11.2J to 30.5J and frequencies from 0 BPM to 700 BPM were investigated. A reduction in excavation force of as much as 51% was achieved in this experimental investigation. Smaller percussive digging implements, tested by others, have achieved a reduction of as much as 72%. This paper will examine the effects of impact energy, frequency, scaling and their effect on excavation forces in a dry granular material such as lunar regolith. The past several years have shown an increasing interest in mining space resources both for exploration and commercial enterprises. This work studied the benefits and risks of percussive excavation and prelimin~ry results indicate that this technique may become an enabling technology for extra-terrestrial excavation of regolith and ice

Zero Horizontal Reaction Force Excavator

An excavator includes a mobile chassis with a first bucket drum and a second bucket drum coupled thereto. The first bucket drum and second bucket drum are coupled to the chassis for positioning thereof on the surface at opposing ends of the chassis. Each first scoop on the first bucket drum is a mirror image of one second scoop on the second bucket drum when (i) the first bucket drum and second bucket drum are on the surface adjacent opposing ends of the chassis, and (ii) the first bucket drum is rotated in one direction and the second bucket drum is simultaneously rotated in an opposing direction

Lightweight Bulldozer Attachment for Construction and Excavation on the Lunar Surface

A lightweight bulldozer blade prototype has been designed and built to be used as an excavation implement in conjunction with the NASA Chariot lunar mobility platform prototype. The combined system was then used in a variety of field tests in order to characterize structural loads, excavation performance and learn about the operational behavior of lunar excavation in geotechnical lunar simulants. The purpose of this effort was to evaluate the feasibility of lunar excavation for site preparation at a planned NASA lunar outpost. Once the feasibility has been determined then the technology will become available as a candidate element in the NASA Lunar Surface Systems Architecture. In addition to NASA experimental testing of the LANCE blade, NASA engineers completed analytical work on the expected draft forces using classical soil mechanics methods. The Colorado School of Mines (CSM) team utilized finite element analysis (FEA) to study the interaction between the cutting edge of the LANCE blade and the surface of soil. FEA was also used to examine various load cases and their effect on the lightweight structure of the LANCE blade. Overall it has been determined that a lunar bulldozer blade is a viable technology for lunar outpost site preparation, but further work is required to characterize the behavior in 1/6th G and actual lunar regolith in a vacuum lunar environment

Electrodynamic Tether

A tether system for providing thrust to or power subsystems of an artificial satellite in a low earth orbit. The tether has three main sections, an insulated section connected to the satellite, a conducting section connected to the insulating section for drawing in and releasing electrons from the space plasma and a non-conducting section for providing a tension to the other sections of the tether. An oxygen resistant coating is applied to the bare wire of the conducting section as well as the insulated wires of the insulated section that prevents breakdown during tether operations in the space plasma. The insulated and bare wire sections also surround a high tensile flexible polymer core to prevent any debris from breaking the tether during use

Comparison of ISRU Excavation System Model Blade Force Methodology and Experimental Results

An Excavation System Model has been written to simulate the collection and transportation of regolith on the Moon. The calculations in this model include an estimation of the forces on the digging tool as a result of excavation into the regolith. Verification testing has been performed and the forces recorded from this testing were compared to the calculated theoretical data. A prototype lunar vehicle built at the NASA Johnson Space Center (JSC) was tested with a bulldozer type blade developed at the NASA Kennedy Space Center (KSC) attached to the front. This is the initial correlation of actual field test data to the blade forces calculated by the Excavation System Model and the test data followed similar trends with the predicted values. This testing occurred in soils developed at the NASA Glenn Research Center (GRC) which are a mixture of different types of sands and whose soil properties have been well characterized. Three separate analytical models are compared to the test data