An Efficient and Versatile Means for Assembling and Manufacturing Systems in Space

Abstract

Within NASA Space Science, Exploration and the Office of Chief Technologist, there are Grand Challenges and advanced future exploration, science and commercial mission applications that could benefit significantly from large-span and large-area structural systems. Of particular and persistent interest to the Space Science community is the desire for large (in the 10-50 meter range for main aperture diameter) space telescopes that would revolutionize space astronomy. Achieving these systems will likely require on-orbit assembly, but previous approaches for assembling large-scale telescope truss structures and systems in space have been perceived as very costly because they require high precision and custom components. These components rely on a large number of mechanical connections and supporting infrastructure that are unique to each application. In this paper, a new assembly paradigm that mitigates these concerns is proposed and described. A new assembly approach, developed to implement the paradigm, is developed incorporating: Intelligent Precision Jigging Robots, Electron-Beam welding, robotic handling/manipulation, operations assembly sequence and path planning, and low precision weldable structural elements. Key advantages of the new assembly paradigm, as well as concept descriptions and ongoing research and technology development efforts for each of the major elements are summarized. Nomenclature

TRUSSELATOR: On-Orbit Fabrication of High-Performance Composite Truss Structures

“…2,3 This "erectables" approach involves launching prefabricated strut components and using astronaut labor or telerobotic systems to connect them together to form truss support structures for large-aperture telescopes. Figure 2 shows examples of prototype components developed by the LaRC efforts, and Figure 3 show a large truss frame for a parabolic reflector assembled in the lab using this erectable technology.…”

Structure assembly by a heterogeneous team of robots using state estimation, generalized joints, and mobile parallel manipulators

“…Onboard sensors must also handle a stark distinction between sunlit 3 N is distinct from the part count due to intermediate steps. 4 To distinguish the experimental LRM and DM from the concepts presented earlier, they will be referred to as the LSMS and IPJR. and shaded components, which was not simulated in the laboratory.…”

“…In recent years, Langley Research Center has developed assembly methods to address some of these challenges [4] by distributing long reach manipulation tasks and precise positioning tasks between specialized agents, employing Simultaneous Localization and Mapping (SLAM) in the assembly workspace, using sequencing algorithms, and detecting and correcting errors. In [5], a heterogeneous team consisting of a long reach manipulator (LRM) and a dexterous manipulator (DM) collaborated to assemble and weld a flat truss made of titanium stock, which required the LRM and DM to collaborate in retrieving struts and nodes from a canister, the DM to position the nodes precisely, and the LRM to weld the struts and nodes together.…”

Relative Robots: Scaling Automated Assembly of Discrete Cellular Lattices

“…Robotic assembly of truss structures has typically taken the form of multi-degree of freedom (DOF) industrial robot arms that place discrete truss segments into larger structural configurations [6]. In order to increase attainable build volume, linear stages are built for the arm to translate around the structure it builds.…”