Advancing Commercial Space

Missions to the moon and other planets will require large-scale infrastructure that would benefit from autonomous assembly by robots without on-site human intervention. Modular and reconfigurable structures, such as those built from lattice-based building blocks, are reusable and easy to manufacture. Furthermore, reconfigurable systems have the potential to outperform traditional, fixed infrastructure in applications that require high levels of flexibility in addition to structural strength and rigidity. NASA Ames Research Center has developed a novel and efficient mobile bipedal robot system to construct low-mass, high precision, and large-scale infrastructure. The mobile bipedal robot system is configured to carry, transfer, and place lattice-based modular unit cells, called voxels, to form a three-dimensional lattice structure. A team of mobile bipedal robots can autonomously unpack and assemble unit cells into functioning structures and systems. The technology provides an integrated system that enables large-scale surface and in-space structural assembly.

Aeronautical and aerospace applications require strong and stiff lightweight materials and structures. The invention relates to a construction system for mechanical metamaterials based on discrete assembly of a finite set of types of parts, which can be assembled in varying orders to produce spatial variation in a range of properties such as rigidity, and auxetic behavior. This system achieves desired material properties through design of the parts such that global behavior is governed by local mechanisms. The invention describes the design methodology, production process, modeling, and experimental characterization of metamaterial behaviors. This approach benefits from incremental assembly that eliminates system deployment scale limitations, best-practice manufacturing of components for reliable, low-cost production, and interchangeability through the use of a consistent assembly process across part types.

Researchers at NASA Ames Research Center have developed an androgynous fastener with high misalignment tolerance characteristics, which is suitable for robotic actuation. This fastener was developed in conjunction with a high-performance building-block structural system that can be robotically assembled by robust collective automated assembly into large, reconfigurable structures ranging from assembly of lunar habitats to terrestrial structures. The fastener mechanisms employ alignment principles similar to the International Berthing and Docking Mechanism (IBDM) in order to relax the positioning requirements of the assembly robots. This novel androgynous fastener provides the desired performance required for robotic assembly of the structural systems and also minimizes or eliminates the problems and disadvantages associated with conventional or traditional fasteners.

The Additive Manufacturing (AM) process uses a 3D printer to convert a filament into a three-dimensional manufactured object by melting the filament and depositing it in built-up layers to form the desired object, where the movement of the printing head is controlled by computer code. The automation of AM is limited and usually still requires human labor workflows, including the fundamental step of removing the finished object from the printer platform. NASA Ames Research Center has developed a novel method to increase automation of AM by embedding additional instructions into the manufacturing toolpath to create manufacturing tools in situ, such as linear springs on the printer platform, and to instruct movement of the printers parts to autonomously move the finished object off the platform. The technology eliminates the need for humans in the loop for high-throughput applications. Testing can also be integrated into the manufacturing toolpath.

On-orbit spacecraft maintenance and repair of components are critical for extending mission lifespans and ensuring operational safety. Traditional inspection methods, like astronaut extravehicular activities (EVAs), are risky and resource-intensive, while fixed cameras offer limited views. To address these challenges, innovators at NASA’s Goddard Space Flight Center developed the Visual Inspection Posable Invertebrate Robot (VIPIR) system, a tele-operated robotic imaging system offering advanced capabilities for visual assessments of space-based assets. VIPIR is a significant leap forward in the realm of on-orbit robotic inspection, evaluation, and servicing systems. Integrating a dexterous, flexible video borescope with advanced articulation mechanisms, VIPIR allows NASA to remotely inspect spacecraft components that would otherwise be difficult or impossible to view, enabling subsequent repairs and maintenance.

Inspired by psychology, these algorithms could be developed and applied towards creating stable, predictable, and artificially intelligent networks. These algorithms collectively represent ways for intelligent systems to identify and correct unpredictable or unstable behaviors, creating stable emotional states that govern behaviors with given specific circumstances, and establishing an evolvable synthetic neural network that can eventually be scaled from low-level functions to higher level decision making processes. These algorithms could be key to research in autonomous spacecraft, nanorobotic swarms, and sensor networks.

NASA and General Motors, two organizations at the forefront of robotics, have developed the Robonaut 2 (R2) – a state-of-the-art, dexterous, humanoid robot capable of performing tasks in an automated fashion (or via teleoperation). The technology developed throughout the project represents the cutting edge of autonomous, humanoid robotics. These technologies are available for licensing, both in a modular framework or as an integrated system, to enhance your robotic products. R2’s 5 Degrees of Freedom (DoF) arms, the topic of this flyer, use series elastic actuation to provide improved shock tolerance, accurate and stable force control, and beneficial energy storage capacity. An impedance controller limits the stiffness of the arms, ensuring workspace safety in scenarios where humans and robots are working in the same environment.

NASA and General Motors, two organizations at the forefront of robotics, have developed the Robonaut 2 (R2) – a state-of-the-art, dexterous, humanoid robot capable of performing tasks in an automated fashion (or via teleoperation). The technology developed throughout the project represents the cutting edge of autonomous, humanoid robotics. These technologies are available for licensing, both in a modular fashion or as an integrated system, to enhance your robotic products. Please see the <i>Related Links</i> section below for information on additional R2 robotics technologies, including those related to arms, interface/control, and sensor systems. R2’s hand and forearm assembly, the topic of this flyer, is designed to approximate closely the capabilities of the human hand. The assembly is a completely self-contained unit featuring high dexterity, fine force control, and advanced sensing that enables the grasping and actuation of a broad array of tools. Relocation of components (e.g., motors, avionics) to the forearm makes room for increased sensing in the fingers and palm, where it is needed most.

NASA and General Motors, two organizations at the forefront of autonomous robotics, have developed the Robonaut 2 (R2) – a state-of-the-art, dexterous, humanoid robot capable of performing tasks in an automated fashion (or via teleoperation). The technology developed throughout the project represents the cutting edge of autonomous, humanoid robotics. These technologies are available for licensing, both in a modular fashion or as an integrated system, to enhance your robotic products. Please see the <i>Related Links</i> section below for information on additional R2 robotics technologies, including those related to hands, arms, and sensor systems. Advanced interface and control technologies, the topic of this flyer, allow R2 (and other humanoid robotics) to achieve safe and effective autonomous or teleoperation-based control. Interfaces enable simple control, while additional control systems ensure safe robot-human interactions, monitor the health of the robotic system, provide fail-safe breaks for robotic electric motors, and ensure electrical connectivity throughout a wide range of potential motions.

NASA and General Motors, two organizations at the forefront of autonomous robotics, have collaborated to develop Robonaut 2 (R2) – a state-of-the-art, dexterous, humanoid robot capable of performing tasks in an automated fashion (or via teleoperation). The technology developed throughout the project represents the cutting edge of autonomous, humanoid robotics. These technologies are available for licensing, both in a modular fashion or as an integrated system, to enhance your robotic products. Please see the <i>Related Links</i> section below for information on additional R2 robotics technologies, including those related to hands, arms, and interface/control systems. Designing a humanoid robot with human-like sensory and perception systems requires an extensive sensor suite (R2 has over 350 integrated sensors). Several novel sensors were developed to accomplish this goal, including a flexible perception system, tendon tension sensor, contact state estimation sensor, and load sensors in the fingers that give R2 its tactile sense (i.e., sense of “touch”).

Innovators at NASA Johnson Space Center (JSC) have developed computer vision software that derives target posture determinations quickly and then instructs an operator how to properly align a robotic end-effector with a target that they are trying to grapple. As an added benefit, the softwares object identification capability can also help detect physical defects on targets. This technology was originally created to aid robotic arm operators aboard the International Space Station (ISS) that relied more heavily upon grappling instructional maneuvers derived from flight controllers on the ground at JSCs Mission Control Center (MCC). Despite the aid of computer-based models to predict the alignment of both robotic arm and target, iterative realignment procedures were often required to correct botched grapple operations, costing valuable time. To solve this problem, NASAs computer vision software analyzes the live camera feed from the robotic arms single borescope camera and provides the operator with the delta commands required for an ideal grasp operation. This process is aided by a machine learning component that monitors the camera feed for any of the ISSs potential target fixtures. Once a target fixture is identified, proper camera and target parameters are automatically sequenced to prepare for grasping operations.

Innovators at the NASA Johnson Space Center have developed a method for controlling precise motion of a Brushless DC (BLDC) motor using relatively inexpensive components. Precision motors are usually quite expensive and inefficient when operating at slow speeds. This technology uses a method to control BLDC motors over a broad range of speeds, ranging from about 0.025 rpm to about 7000 rpm. Its ability to operate at these ranges and with high precision provides an opportunity to integrate this technology to many applications and industries. Commercial motors may employ this technology to extend their dynamic range. This technology can also be integrated into surgical robots that require advanced precision motion control systems. Hybrid and electrical vehicles can integrate this technology to their operating system to improve efficiencies.

Innovators at the NASA Johnson Space Center (JSC), in collaboration with Oceaneering and The Florida Institute for Human and Machine Cognition, have developed the Split-Ring Torque Sensor (SRTS), a device that uses optical sensors to measure the position, velocity, and torque of a rotating system. The SRTS was created for use in NASA's X1 robotic exoskeleton, an in-space, wearable exercise machine designed to supply resistance against leg movement for NASA astronauts in future missions. The X1 exoskeleton implements the SRTS in its belt-drive series elastic actuator (SEA) and provides a lower profile and lower weight system than competing designs. The SRTS offers greater flexibility in tailoring for specific applications and requirements. In addition to its applications in robotics, the SRTS has potential uses in medical fields including prosthetics, aerospace & defense applications, automotive applications, testing & measurement, and industrial markets.

Innovators at NASA Johnson Space Center have designed a spherical joint which allows up to six linearly actuated links or attachments to rotate about a co-located center. Originally designed to provide joint flexibility necessary for a variable geometry truss system, the new spherical joint also allows power and data lines to pass through it without the lines being subjected to structural forces. This technology can be key for creating a deployable, variable geometry truss system, with a compact form factor that can reduce payload volume within the confines of a launch or other transport vehicle. Typically, flexible truss systems rely on joints where each of the links do not rotate around the same point, creating instability in the joints and the entire structure. The Multi-Link Spherical Joint removes those instabilities, allowing for a durable and adaptable technology with multiple space and terrestrial applications.

Innovators at NASA Johnson Space Center have designed an Active Debris Removal Vehicle (ADRV) that can remove large orbital debris from low-Earth orbit (LEO). The ADRV will approach a debris object, assess its characteristics and motion, determine an initial capture trajectory, match its rotation rates, execute a capture maneuver, and control and deorbit the object. This concept can help mitigate catastrophic collisions with debris involving astronauts, their spacecraft, and other valuable space assets. The ADRV incorporates several NASA inventions including a novel spacecraft control system, debris object characterization system, and capture and release system. These NASA ADRV technologies may also be applied to satellite servicing and orbital adjustments. The Active Debris Removal Vehicle (ADRV) is at technology readiness level (TRL) 6 (which means the system/sub-system model or prototype has been demonstrated in an operational environment) and the related issued patent is now available to license. Please note that NASA does not manufacture products itself for commercial sale.

In-space and planetary surface assembly for human exploration is a challenging domain that encompasses various technological thrusts to support human missions. NASA is developing autonomous assembly agents to build structures like habitats and antennae on the Moon. These modular and reconfigurable Assembler robots will provide robotic assembly of structures, even in locations that prohibit constant human oversight and teleoperation. This system is capable of scheduling, reconfiguring, and executing structural assembly tasks; assessing construction; and correcting errors in assembly as needed. On command, the Assemblers stack themselves into robot team members for the task. For example, a few Assemblers might build a solar array as shown in the above image. The Assembler technology builds upon recent advancements in lightweight materials, state estimation, modern control theory, and machine learning. The Assembler technology builds upon recent advancements in multi-agent planning, state estimation, modern control theory, and machine learning. Compared with existing short-reach/high-accuracy and long-reach/low accuracy-assembly robots, Assemblers provides both long- and short-reach capability with accuracy and precision. NASA has developed a prototype of the technology and seeks companies that are interested in licensing the technology and commercializing it for space or other applications.

NASA researchers have developed a novel process for assembling thin-film solar cells into larger solar arrays. Current methods for solar array manufacturing depend on time-consuming, manual assembly of solar cells into multi-cell arrays. Print-assisted photovoltaic assembly (PAPA) is an assembly process that leverages robotic automation to build fully functional flexible thin-film solar arrays. By increasing manufacturing efficiency, PAPA's no-touch technology can reduce labor costs, decrease time-to-market, and enable assembly of large-scale solar arrays of over 500kW. This increased efficiency can help meet growing demand for large solar arrays in residential and satellite applications. Compatible with all currently available thin-film and 3D-printed solar cell materials, PAPA is capable of integrating with current and future solar cell technologies. NASA is seeking licensees that may benefit from low-cost, automated assembly of large-scale solar arrays.