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HST Robotic Servicing Mission

Final Report
Jay Loftus Sarah Razzaqi Sandra Mau Wing Chan December 3, 2004

Acknowledgements
For their continued support, advice, and education Team X-Site wish to thank the following people at MDRobotics and University of Toronto: Paul Fulford MDRobotics Course Coordinator Tim Reedman MDRobotics Systems Coordinator Ross Gillett MDRobotics Electrical Coordinator Tim Fielding MDRobotics Mechanical Coordinator Perry Newhook MDRobotics Software Coordinator Professor Chris Damaren University of Toronto Course Coordinator Luke Stras Teaching Assistant (University of Toronto)

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Abstract
The Hubble Space Telescope has been in service since 1990. Currently, the Hubble is approaching a point where significant maintenance is required. Its ability to perform scientific research has been hindered by aging power sources and it may loose the ability to stay in orbit by 2009. NASAs proposed servicing mission involves the use of a launch vehicle called the Hubble Robotic Vehicle (HRV). It will contain a De-orbit Module, Ejection Module, and two robotic manipulator systems: Grapple Arm (GA) and Dexterous Robot (DR). The purpose of this launch vehicle and its robotic systems is to avoid Extra Vehicular Activity (EVA) performed by astronauts and the use of a space shuttle. The focus of this report will be on the design of the GA. Our final design solution involves an arm that is approximately 12m in length that can reach the entire servicing workspace. It will have the capability to capture Hubble as well as the Dexterous Robot without causing damage to either system. The arm will have six degrees of freedom and have the capability to be tele-robotically controlled as well as being autonomous at certain mission stages. It will incorporate 4 cameras and a Laser Range Finder to assist in guidance and capture. In short, our system achieves all the requirements, and attempts to use the most efficient method available.

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Table of Contents
ACKNOWLEDGEMENTS ........................................................................................................ II ABSTRACT.................................................................................................................................III TABLE OF CONTENTS ........................................................................................................... IV NOMENCLATURE AND ACRONYMS ............................................................................... VII INTRODUCTION......................................................................................................................... 8 PROJECT CONCEPT AND DESIGN PARAMETERS .......................................................... 9 MISSION OBJECTIVES ................................................................................................................... 9 MISSION REQUIREMENTS ............................................................................................................. 9 GRAPPLE ARM REQUIREMENTS ................................................................................................. 11 SYSTEMS.................................................................................................................................... 12 INTERFACES ............................................................................................................................... 12 SYSTEM BLOCK DIAGRAM ......................................................................................................... 13 FUNCTIONAL FLOW BLOCK DIAGRAM ....................................................................................... 14 AUTONOMY ............................................................................................................................... 18 GROUND CONTROL ARCHITECTURE........................................................................................... 19 MECHANICAL .......................................................................................................................... 20 FUNCTIONAL REQUIREMENTS .................................................................................................... 20 PERFORMANCE REQUIREMENTS ................................................................................................. 20 PERFORMANCE REQUIREMENT ANALYSIS.................................................................................. 20 Speed ..................................................................................................................................... 20 Force/torque ......................................................................................................................... 22 Joint Angle Calculation ........................................................................................................ 22 GA Worst Case Capture Scenario ........................................................................................ 23 Precision ............................................................................................................................... 24 WIRING ...................................................................................................................................... 25 BOOM ........................................................................................................................................ 25 Type of Structure................................................................................................................... 26 Material................................................................................................................................. 27 Number and Length of Booms............................................................................................... 27 Final Boom Configuration.................................................................................................... 27 JOINTS ........................................................................................................................................ 28 Joint Selection....................................................................................................................... 28 Actuation ............................................................................................................................... 29 Material................................................................................................................................. 30 Joint Motor and Gearboxes .................................................................................................. 32 FINAL JOINT SELECTION ............................................................................................................ 34 ELECTRONIC COMPONENT CASINGS .......................................................................................... 35 THERMAL/ENVIRONMENTAL CONTROL ..................................................................................... 35 Passive Control..................................................................................................................... 37 Thermal Blankets / Multilayer Insulation (MLI) .................................................................. 37 IV

Radiators............................................................................................................................... 38 Active Control ....................................................................................................................... 39 LUBRICANTS .............................................................................................................................. 39 JOINT SENSORS POSITION, VELOCITY, FORCE .......................................................................... 40 END EFFECTORS......................................................................................................................... 41 Type....................................................................................................................................... 41 Force/Torque Sensors........................................................................................................... 42 Material................................................................................................................................. 43 Final Design.......................................................................................................................... 44 SNARE MOTOR AND GEARBOX SELECTION ................................................................................ 45 VISION SYSTEMS ........................................................................................................................ 46 TIE DOWNS SELECTION.............................................................................................................. 48 Type/Release Mechanism...................................................................................................... 48 Location ................................................................................................................................ 51 ELECTRICAL ............................................................................................................................ 53 ELECTRICAL REQUIREMENTS ..................................................................................................... 53 FUNCTIONAL REQUIREMENTS .................................................................................................... 53 PERFORMANCE REQUIREMENTS ................................................................................................. 53 ELECTRICAL ARCHITECTURE ..................................................................................................... 53 CABLING .................................................................................................................................... 65 POWER ....................................................................................................................................... 65 POWER REQUIREMENTS ............................................................................................................. 65 Electrical Components.......................................................................................................... 65 MISSION STAGES........................................................................................................................ 67 SOFTWARE................................................................................................................................ 70 REQUIREMENTS.......................................................................................................................... 70 SYSTEMS CONTEXT DIAGRAM ................................................................................................... 72 DATA DICTIONARY .................................................................................................................... 75 CONTROL SYSTEMS............................................................................................................... 76 ACTUATOR & SENSOR SELECTION ............................................................................................. 77 Required Components........................................................................................................... 77 CONTROL ARCHITECTURE.......................................................................................................... 78 SIMULATION WITH MATLAB.................................................................................................... 81 GA AND DR INTERFACING................................................................................................... 90 MECHANICAL INTERFACE .......................................................................................................... 90 End Effector and DR Grapple Fixture.................................................................................. 90 Capture Envelope.................................................................................................................. 91 Loads..................................................................................................................................... 91 Thermal Interfacing .............................................................................................................. 91 ELECTRICAL INTERFACE ............................................................................................................ 93 Power .................................................................................................................................... 93 Data....................................................................................................................................... 93 SOFTWARE INTERFACE .............................................................................................................. 94 V

30% POWER REDUCTION PROPOSAL .............................................................................. 99 COMPLIANCE TABLE ............................................................................................................ 99 CONCLUSIONS ......................................................................................................................... 99 APPENDIX A ............................................................................................................................ 102 A1: A2: A3: A4: A5: A6: FULL FUNCTIONAL FLOW BLOCK DIAGRAM (FOR HRV + GA + DR)............................. 102 FUNCTIONAL FLOW AND HAZARD CONTROLS ................................................................. 116 RS 422 SPECIFICATIONS .................................................................................................. 123 MIL-STD-1553B SPECIFICATIONS .................................................................................. 124 DR STOPPING CALCULATIONS ......................................................................................... 125 REFERENCES .................................................................................................................... 125

APPENDIX B ............................................................................................................................ 126 B1: TORQUE CALCULATIONS ................................................................................................... 126 B2: TORQUE & POWER REQUIRED FOR SNARE MOTORS ........................................................ 127 B3: SPEED REQUIREMENT CALCULATIONS ............................................................................. 128 B4: GA BOOM ANALYSIS ........................................................................................................ 129 B5: HST CAPTURE SCENARIO ANALYSIS ................................................................................ 130 B6: HEAT TRANSFER ............................................................................................................... 132 B7: REFERENCES ..................................................................................................................... 133 APPENDIX C ............................................................................................................................ 134 C1: CABLING MASS CALCULATIONS ...................................................................................... 134 Data Lines:.......................................................................................................................... 134 Power Lines: ....................................................................................................................... 134 Video Lines.......................................................................................................................... 135 C2: REFERENCES .................................................................................................................... 138 APPENDIX D ............................................................................................................................ 139 D1: PRECISION CALCULATIONS .............................................................................................. 139 D2: SOFTWARE DESCRIPTION ................................................................................................. 140 D3: REFERENCES .................................................................................................................... 152

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Nomenclature and Acronyms


DR Dexterous Robot EE End Effector EM Ejection Module EMGF Electro-Mechanical Grapple Fixture GA Grapple Arm GC Ground Control GF Grapple Fixture EVA Extra Vehicular Activity FFBD Functional Flow Block Diagram HRV Hubble Repair Vehicle HST Hubble Space Telescope LEO Low Earth Orbit WFC Wide Field Camera

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Introduction
The Hubble Space Telescope (HST) is one of the most remarkable scientific achievements in human history. It has been in service since 1990 and the National Aeronautics and Space Administration (NASA) wish to extend its service life. Currently, the Hubble is approaching a point where significant maintenance is required. It is experiencing degradation in scientific capabilities, loss of power, and has an aging battery that is steadily losing charge capacity. However, the most important concern is the loss of stability control. NASA projects that the HST will have fewer than two operating gyros by mid 2007, which will cause an uncontrolled decent through the atmosphere and impact on Earth. Thus, the main objectives of this mission will be to provide HST with the capability to de-orbit, increase its operational lifetime by at least five years, and enhance its scientific capabilities by installing new instruments. NASAs proposed servicing mission involves the use of a launch vehicle called the Hubble Robotic Vehicle (HRV). It will contain a De-orbit Module, Ejection Module, and two robotic manipulator systems: Grapple Arm (GA) and Dexterous Robot (DR). The purpose of this launch vehicle and its robotic systems is to avoid Extra Vehicular Activity (EVA) performed by astronauts and the use of a space shuttle. If a servicing mission cannot be launched by 2008, then HST will be placed in safemode to allow for a launch date of 2009 at the latest. However, to reduce risk and minimize the interruption to HST scientific operations, the HRV should be launched by mid 2008. The focus of this report will be a potential design of the Grapple Arm manipulator system. Its goals will include capture and docking with Hubble as well as perform servicing operations through the capture and positioning of the DR. This report will provide a detailed description of the design process including Interfacing and Robotic Autonomy Concepts, breakdowns of subsystem components such as Software, Mechanical, and Electrical Systems.

Project Concept and Design Parameters


MISSION OBJECTIVES
The success of the Hubble Robotic Servicing Mission depends on the successful completion of three main mission objectives; capture of HST, berthing of Deorbit Module to HST, servicing of HST. These objectives require that the two robotic manipulators carry out the following tasks. GA captures either of HSTs two grapple fixtures GA berths DM to HST GA retrieves DR and aids it in servicing tasks o DR replaces the P6A and P8A connectors in the HST Diode Box 2 to harness power from the HST SA3 for battery augmentation o DR installs the power and data conduit o DR installs the WFC3 camera o DR establishes data connection for gyros GA stows DR for re-entry GA stows itself for re-entry

MISSION REQUIREMENTS
In order to achieve the mission objectives outlined in the previous section, the robotic manipulators must be designed to meet the following requirements as laid out by NASA in the Mission Concept Review presented in May of 2004. Only the mission requirements that are relevant to the design of the GA are presented here. Level I Requirements The following requirements re-iterate the mission objectives identified earlier. Provide the capability to safely and reliably de-orbit HST at the end of its useful scientific life Provide the capability to robotically extend the scientific life of HST for a minimum of 5 (TBR) years Provide robotic installation of the WFC3 and COS instruments Provide single-fault tolerance for the de-orbit mission Ensure that Level I performance is not degraded by robotic servicing

Level II Requirements The HRV encompasses both the GA and DR. The successful completion of the tasks related to docking and disposal require that the GA to capture HST. The life extension tasks are performed by the DR using the GA as a servicing platform. The HRV shall be capable of pursuit, proximity operations, capture, and docking with the HST

The HRV shall be capable of achieving pursuit, proximity operations, capture, and docking with the HST from an initial ELV-provided orbit of TBR km The HRV shall be capable of performing a controlled de-orbit of HST in accordance with controlling the odds of human casualty as specified in NPD 8710.3A The HRV shall be capable of performing a controlled de-orbit of HST for a minimum of seven years (EOL) from launch The HRV shall support HST life-extension with battery and RSU augmentations The HST life extension provided by the HRV shall be for a minimum of five (TBR) years from the completion of servicing The HRV shall provide the means to install WFC3 in place of the WF/PC2 radial scientific instrument and install COS in place of the COSTAR axial scientific instrument

Level III Requirements The following requirements relate to the pursuit, proximity, operations, capture, and docking with HST. The HRV shall be capable of rendezvous with HST at a maximum altitude of 560 km The HRV shall be capable of capturing and docking with HST with the HST in an unpowered drift having body rates up to +/- .22 deg/sec (TBR) magnitude in each of three axes simultaneously The HRV shall provide controlled thruster plume impingement on the HST to avoid HST attitude responses and mechanical damage to HST appendages, and to minimize contamination and plume heating to any portion of the HST o Solar Array Torque shall not exceed 4.5 in-lb about V2 Axis o HST torque in each of V1, V2 V3 shall not exceed 9.35 in-lb about the HST CG The HRV design shall make it possible to keep the HRV out of the sweep range of the HST solar arrays and the high gain antennas during capture and docking, as well as after docking HRV shall be capable of a minimum of four capture/docking attempts The HRV shall provide two independent means of capturing HST The HRV shall capture HST using one of the following hardpoints: either of the two grapple fixtures, the FSS berthing pins on the aft bulkhead, either of the two trunnions located on the +/-V3 sides of HST, or the HST keel fitting The HRV shall be docked to the HST using the three HST berthing pins The axes of the HRV coordinate system shall be parallel to the respective axes of the HST coordinate system The HRV shall maintain at least a one-inch static clearance between the HST and the HRV (except at designed structural load path) The docked HRV shall provide 2 (TBR) inches of clearance to the HST P105 and P106 connectors for contingency umbilical mate by robotic means During capture and docking operations, loads into each HST berthing pin shall not exceed those defined in table 1 Aft Bulkhead Allowables A contingency ground abort capability shall exist for all autonomous HRV operations The HRV shall provide video transmission of rendezvous, capture, and docking with HST. Resolution and frame rate shall support ground supervision of critical operations

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The HRV shall redundantly acquire range rate (relative to the HST) data using different types of sensors systems The HRV command link shall utilize authentication and encryption

The following requirements relate to the life extension via gyro/battery augmentation and science instrument replacement. The GA aids the DR during this phase of the mission. Tele-robotic methods shall be used for servicing The three RSUs shall be mounted on the OTA structure via the WFC3 instrument The command and telemetry of the RSUs shall be through the HST 486 computer The DM batteries shall provide a minimum of 300 Ah of augmentation at 6 years for HST utilization SA3 shall provide the primary power source for HST Battery Augmentation. The DM power feed to HST shall be through the aft bulkhead J101 umbilical (P105, P106 as contingency) The HRV shall provide environmental protection that meets the Science Instruments and Dexterous Robot requirements for all mission phases as specified in ST-ICD- 02/ 03, Robot user guide (TBD) During life extension operation, loads into each FSS berthing pin must be limited as defined in table 1 Aft Bulkhead Allowables All thermal systems must be verified in a 1 g ground test

GRAPPLE ARM REQUIREMENTS


Based on the above mission requirements, functional and performance requirements can be derived for the GA system, more specifically for each subsystem of the GA. These requirements are presented in the sections describing the individual subsystems. The subsystems were designed to meet these derived requirements.

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Systems
INTERFACES
Defining system boundaries and constraints is a key step in designing an effective and efficient system. The following sections outline the HRV system interfaces. Interface GA Avionics to EM GA Avionics to GA (internal) GA to EM GA to HST GA to DR DR Avionics to EM (via GA) EM to Ground Control Ground Control to GA Ground Control to DR DR to EM DR to HST DR to WF/PC II DR to WFC3 DM to EM DM to HST Characteristics - RS 422 serial data interface - Parallel power at 28VDC nominal - Command and data transfer - Parallel MIL-STD-1553B Data Interfaces - Parallel power supplies at 28VDC nominal - Deck mount for arm base - GA storage mounts and latches - Grapple Arm EE / HST GF interface - Grapple Arm EE / HST GF interface - Redundant power and data plugs - Parallel RS 422 serial data interfaces - Parallel power supplies at 28VDC nominal - Satellite based communication system - GA EE video feed to ground control - Tele-robotic operation commands from ground control to GA - Autonomy operation commands from ground control to GA - GA EE video feed to ground control - Tele-robotic operation commands from ground control to GA - Autonomy operation commands from ground control to GA - Temporary stowage fixtures inside cargo bay - DR EE on P6A and P8A connectors - DR EE on power and data conduit - EE on A-Latch, Blind Mate Connector and Ground Strap - EE to physical handhold on camera - EE to physical handhold on camera - EE on A-Latch, Blind Mate Connector and Ground Strap - EE to Rate Sensing Unit (RSU) connectors - Docking latches - Power and data interface - Docking latches - Power interface

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SYSTEM BLOCK DIAGRAM


This section presents the system block diagram for Team X-Sites GA Design. The system block diagram graphically depicts the interfaces and subsystems for the HRV.

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FUNCTIONAL FLOW BLOCK DIAGRAM


After determining what our mission objectives, mission requirements, and mission constraints were, we constructed a behavioural model for our mission, in the form of an FFBD. The following contains only the portions of the FFBD dealing with the GA. The full FFBD is located in Appendix A. The hazards alongside the text version of the FFBD is also found in Appendix A. HRV (Grapple Arm and Dexterous FFBD)
1 Launch & Pursuit 2 Proximity Operations 3 Capture 4 Servicing 5 EM Jettison & Disposal

1. Launch & Pursuit


1.1 GA in tie-down position on EM surface 1.2 DR in stowaway position inside isolated cargo bay

2 Proximity Operations
2.1 As HRV prep for capture, power up GA and run system check

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3 Capture
3.1 Release pins tying GA down 3.2 GA deploys/unfolds 3.3 GA runs full system check and functional simulations 3.4 GA assumes ready to capture pose 3.5 HRV positions HST GF in Capture Box, allowing GA to acquire the GF target

3.6 Ground Control monitors HST through video, determines HST roll rates and GF capture windows

3.7 In a GF capture window Gnd Ctrl adjusts GA position /orientation enabling ready to capture conditions

3.8 Ground Control tele-robotically controls GA EE to surround HST GF

3.9 EE captures HST GF and brings HST to near rest relative to HRV

3.10 GA movement enabled to join HRV and HST modules together

3.11 GA releases HST GF and folds up to dormant position

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3 Servicing
General operations of GA and DR that are performed repeatedly for each service task is outlined in detail below (4a) and referenced therafter

4a GA takes out DR to perform servicing operations


4a.1 GA deploys/unfolds 4a.2 DR cargo bay door opens via ground control 4a.3 GA uses EE camera to locate the EMGF on DR. 4a.4 Predictive displays project the current positions of GA EE and DR EMGF 4a.5 GA, telerobotically controlled, keeps DR EMGF in view while reaching towards it with GA EE

4a.6 GA EE captures DR EMGF

4a.7 GA connection allows DR to power up

4a.8 EM releases pins/bolts/straps on launch locks holding DR down

4a.9 GA autonomously maneuvers DR out of cargo bay by linear retraction, and video verification

4a.10 DR unfolds in space and does a full system check

Servicing tasks to be performed


4.1 Conduit Deploy/ Battery Augmentation 4.2 Change-out for WFC3 4.3 Change-out for RSU

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4.2 Stow DR
4.4.1 DR folds into stow configuration 4.4.2 GA moves directly over DR cargo bay 4.4.3 GA telerobotically lowers DR into the DR cargo bay to within 0.16 accuracy. 4.4.4 Stowing latches fix DR in stow position 4.4.5 DR shuts down.

4.4.6 GA EE detaches power/data plugs from DR EMGF

4.4.7 GA EE releases DR EMGF and retracts 2m linearly back

EM Jettison & Disposal


5.1 DR back in stow-away position inside isolated cargo bay 5.2 GA folds back to original tie-down position on EM surface, reattaching the physical binds 5.3 Ground control sends signal for EM to detach from DM 5.4 EM performs evasive maneuvers to navigate away from HST 5.5 EM performs deorbit burns to reenter and burn up in atmosphere along with GA and DR

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AUTONOMY
The choice between autonomous and telerobotic operation for the various phases of the mission is dictated primarily by the time sensitivity and required precision of a given task. Tasks that cannot be performed properly with a time lag (on the order of seconds) cannot be performed telerobotically. For capturing the HST GF we have determined that autonomy is in fact not required. The entire HST GF capture sequence may be done telerobotically by a ground operator. The largest obstacle in the capture of the HST GF is the time delay between the Ground Control and the HRV introduced in the satellite communication system. The time delay is estimated to be from 5-7 seconds[1]. This time delay, although seemingly large, is within tolerances for our capture sequence. Our capture envelope consists of a circle that is 34 cm in diameter (see Interface Connection for GA and DR: Capture Envelope). We have also determined that the maximum magnitude of speed for the HST GF before capture will be 1.4 cm/s. If the telerobotic operator were to centre the GA EE directly over the GF shaft on his monitor, at most the operator would be off by 9.8 cm. The capture envelope of the GA EE can allows the operator up to 17 cm leeway. Thus in a telerobotic situation the operator still has 7 cm of leeway for capture.

Fig. Telerobotic GF Capture Analysis In addition, predictive displays could analyze mission data and use simulated models of the GA and HST in order to project the current positions of the GA and HST and minimize the time delay error[1]. The capture of the DR GF is a simpler case of the HST GF capture since the DR will not be rotating relative to the GA during capture. Thus the DR GF will be captured in a similar manner as the HST GF. The DR will be extracted from the cargo bay in linear path to prevent snagging and damage to the DR. The linear path will need to be slow and precise in order to minimize possible damage to the DR. Since speed is not required in this task we chose to complete this task telerobotically keeping the implementation of this task as simple as possible. Furthermore, the telerobotic implementation of extracting DR simplifies any maneuvers required in problem solving should the DR become stuck during extraction. The GA force/torque sensors and stop the extraction if

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unexpected loads occur. Thus, telerobotics is not only the simplest method, but also the safest method to extract the DR from its stowage bay. In contrast to GF capturing, the positioning of the dexterous robot during servicing is not a timedriven aspect of the mission. In that regard telerobotics could be used. However, the precision required in placing the DR (0.16 as specified by NASA) is beyond the capabilities of a telerobotic operator. Thus the positioning of the DR during servicing will have to be carried out autonomously. There will still be interaction with ground control in the form of commands to initiate or terminate a task. Ground control will also monitor the mission at every step. Any GA path will still be confirmed by the ground control before the GA carries it out. But tele-robotic operation of the grapple arm from ground control will be limited to failure modes only. Finally, calculations from our partner team have shown that the stowing of the dexterous robot is less than or equal to the precision requirements for the grapple arm already specified by NASA. Thus the lack time driven requirements or need for greater precision led to the decision to also carry out the stowing of DR telerobotically. This task will have to be monitored from ground control to ensure that the latches are securely in place. In fact, all tasks will be monitored by ground control with checks and command confirmations worked into the software of both the grapple arm and dexterous robot.

GROUND CONTROL ARCHITECTURE


From the functions previously defined we can determine the necessary components of a ground control station. The mission is balanced with telerobotic and autonomous tasks, so the function of ground control is to coordinate telerobotic operations and to give initiate and terminate commands for autonomous tasks. At this point four major ground control elements have been identified and are shown in the flow diagram below. Ground Control

Tele-robotics
-tele-robotic operator uses video feed and sensor information to control grapple arm

Health Monitoring
-monitor sensor data from thermal sensors, booms stress sensors, end effector force and torque sensors and video feed -alert Communications if sensor readings exceed limit levels

Communications
-responsible for sending and receiving commands from GA and DR including confirmation messages, initiate and terminate task messages, emergency messages etc -monitor communications between GA and DR to ensure link is active -monitor satellite positions and availability to ensure that communications between ground control and manipulators is always active

Performance
-monitor mission to ensure that mission objectives are being met to within requirements -suggest changes to mission protocols to improve mission performance if necessary

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Mechanical
This section will incorporate the reasons for selecting our mechanical components such as joints, booms, vision systems, and end effector.

FUNCTIONAL REQUIREMENTS
1. The GA must provide means to grapple either Hubble Space Telescope (HST) Grapple Fixture (GF). 2. The GA must provide means to grapple the Dexterous Robot (DR). 3. The GA must provide power and data connections to the DR 4. The GA must provide a vision system to aid grappling HST and completing servicing tasks. 5. The GA must position and orient the DR for servicing. 6. The GA must do no harm to HST.

PERFORMANCE REQUIREMENTS
1. The GA must have open loop accuracy of less than 1.5 and 2. 2. The GA must have position repeatability of 0.16. 3. The GA shall be capable of capturing and docking with HST in an un-powered drift having body rates up to 0.22/s magnitude in each of three axes simultaneously. 4. The GA shall withstand the forces associated with stopping a 1000 lb mass from the maximum tip velocity of the DR in 2 or 2.5. 5. The GA shall be able to reach all points in the workspace (defined by the DR) during servicing.

PERFORMANCE REQUIREMENT ANALYSIS


Speed In a worst case scenario HST will be spinning at 0.22/sec in 3-axis at the time of HRV/HST rendezvous. Assuming that the HST GF are directly above the centre of mass of HST and that the radius of HST at that point is 2.1m we can calculate the maximum speed of the GF. The maximum speed of the GF in any direction and at any time would be: VGF_MAX = sqrt( 3 * (0.22/sec * pi rad/180 * 2.1m/rad) = 0.013966255 m/s ~ 0.014 m/s At the time of the HRV/HST rendezvous the HRV will be ~5-8 m away from the HST1. So, the maximum distance the EE will have to travel to reach the GF will be 8 m. Before the sequence for capturing the HST GF begins the GA can be moved within 4 m of the HRV, so that the GF will only have to travel at most 10 m to capture the GF. Since the HRV is spinning at 0.22/sec max, this will allow a capture window time of :
1

MCR_6s00-6s11 pg.48

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180/0.22/sec = 818 sec or 13 min 38 sec If we use a FOS of 1.5 for the capture sequence (so we can move the GA EE away from the HST at any time) for the capture sequence we will have ~ 9 min 5 sec to move to the GF, attempt to snare the GF and slow HST or back the GA EE away if the snare is unsuccessful. Here is a basic timeline for the capture attempt sequence: Locate HST GF, move within the capture envelope of the GA EE Attempt to snare HST GF Slow Hubble Remove GA EE from HST if snare unsuccessful < 4 min 2 sec 50 sec 10 sec < 4 min 2 sec

Sub-Timeline: Locating GF and moving GA EE so HST GF is within its capture envelope: Manually move GA EE within 2 m of HST GF (at 0.06 m/s) t ~ 1 min 40 sec Lock auto control of GA EE onto HST GF t ~ 10 sec Move GA EE within 1 m of HST GF (at 0.06 m/s) t ~ 17 sec Move GA EE within 0.5 m of HST GF (at 0.03 m/s) t ~ 17 sec Move GA EE into capture envelope around HST GF (at 0.01 m/s) t ~ 50 sec Total t ~ 3 min 31 sec From the spinning of HST GF and the max speed of the GA EE relative to HST we can determine that the maximum speed of the GA EE will have to be: 0.06m/s + 0.014m/s = 0.074m/s ~ 7.5cm/s Now from the maximum speed of the GA EE we can determine the maximum angular velocities required for the joints. To determine the maximum angular velocities required by the joints we can look at the worst case where the GA is extended to its longest working length and moving away from the base of the GA at max speed. We have determined the angles required for worst-case situation for grappling the HST GF in the Joint Angle Calculations section below. Where L1 = 5.7 m, L2 = 5.92 m, L3 = 0.82 m, theta1 = 1.078 rad, theta2 = 0.8231 rad, theta3 = 1.2405 rad. Thus, from the Jacobian2 we can determine the maximum angular velocities required given that V = [x_dot; y_dot; _dot] = [0; 0.075m/s; 0] Vangle = J-1*V = [1_dot; 2_dot; 3_dot] = [0.017; -0.0322; 0.0152]

Controls Workshop Handout, by Prof.Damaren

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Therefore, the max angular velocity occurs at the elbow joint and is 0.0322 rad/s, which is equivalent to 0.3075 rpm. Force/torque The worst-case scenario for torque is during the capture of the HST. The detailed calculation is outlined in Appendix B: Torque Calculations. The joint torques can be found based on the end effector forces and torques through this relation:

The Jacobians actual values are found in Appendix B: Speed Requirement Calculations. The max EE torque was found to be 158.4 Nm.

T1 T 2 T3

Fx = J Fy Tz
T

- 3.7448 - 9.5901 1 = - 4.1782 - 3.9066 1 0.6569 - 0.4907 1 158.4 Nm = 158.4 Nm 158.4 Nm

0 0 158.4 Nm

So in the worst case our torques will need to withstand 158.4 Nm of torque. Thus, our required torque for each joint is 158.4 Nm. Joint Angle Calculation In order to conduct the following analysis, it was assumed that the GA operates only in the pitch plane. This approximation is sufficient in determining most relevant arm parameters, including the arm configuration during capture.

ibid

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The worst case scenario for arm configuration during capture is when the HRV approaches HST from behind with the major axis of HST in line with the major axis of HRV. (Please see below for rough layout.) This case may cause the arm to fully extend, which is not desirable. In addition, this case defines a required workspace radius of sqrt(10.6^2 + 0.082^2) = 10.65 m. In fact, upon performing the calculations for the 5m boom length GA, it was found that the arm would be very near to fully extended during capture. Thus, the arm boom length was increased to 5.5m, which was sufficient for this worst-case capture scenario. With these new boom lengths the joint angles were computed to be: 1 = 47.2 2 = 61.8 3 = 71.1 (Arises from Assumption 8 defined below). These angles are later used to compute joint motor speeds and torques. The assumptions and equations used in this analysis are presented below.

HST

HST Solar Array

HST Grapple Fixture DM

GA

EM

GA Worst Case Capture Scenario Assumptions: 1) GA operates primarily as a pitch-plane robot during capture. 2) HRV and HST are of the same diameter. 3) GA shoulder joint is placed right at edge of EM. 4) A 2m maximum separation distance exists between HRV and HST for capture. 5) Dimensions of DM, and DM/EM connection are as given in NASA MCR i.e. DM height = 60 in, DM/EM connection height = 21 in. 6) HST Grapple Fixture is located 21.5 ft from bottom of HST. 7) Each joint is 20 cm in diameter and 22 cm in height. 8) Wrist is parallel to x-axis (as defined below) =180 deg. The following diagram defines the variables used in this analysis.

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l1 = (half diameter of shoulder pitch joint) + (boom length) + (half diameter of elbow pitch joint) = 0.1 + 5.5 + 0.1 = 5.7 metres l2 = (half diameter of elbow pitch joint) + (boom length) + (height of wrist yaw joint) + (half diameter of wrist pitch joint) = 0.1 + 5.5 + 0.22 + 0.1 = 5.92 metres l3 = (half diameter of wrist pitch joint) + (height of wrist roll joint) + (wrist boom length) + (end effector length) = 0.1 + 0.22 + 0.2 + 0.3 = 0.82 metres The following equations are used in the analysis. (Reference: AER402 Course Notes) px = x l3cos = l1cos1 + l2cos(1 + 2) py = y l3sin = l1sin1 + l2sin(1 + 2) c2 = (px2 + py2 - l12 + l22)/ 2 l1l2 c1 = ((l1 + l2c2) px + l2s2 py)/( px2 + py2) 3 = - 1 - 2 With location of end effector tip (x, y) given as x = 0 and y = 2 metres + 21.5 ft + 60 inches + 21 inches = 10.6106 metres. (Based on Assumptions 3 to 6) Precision The GA precision requirement as outlined in the MCR (i.e. position repeatability of 0.16 inches), was determined to be the driving precision requirement. Using a simplified analysis, this tip precision was converted to a joint precision, which in turn provides a specification for the types of joint sensors required.

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The worst-case scenario for this analysis is with a fully extended arm (i.e. 3 = 0, 2 = 0, and 1 = any angle). Assuming that the arm starts in a position such that 1 = 0 as well, to find the necessary joint angle precision, move the arm tip position 0.16 inches and determine the new joint angle 1. The analysis was simplified by assuming that the 0.16-inch separation occurs along the arc formed by moving the tip from a point A to a point B. This assumption is conservative since assuming an arc length of 0.16 inches results in a straight-line separation between point A and B of less than 0.16 inches. Given this, the joint angle is computed to be: 1 = 0.16 inches / 12.44 metres = 0.0187 A more rigorous analysis could be carried out using forward and inverse kinematics, but this simplified analysis is sufficient in determining joint sensor specifications. Thus, it was determined that a 16-bit resolver would be needed to measure joint angles to the required precision.

WIRING
For the wire selection we used the SAE-AS22759-11 document. For our data purposes we will use a STD-1553b serial data bus. The data signals will be 0-5V, resistance of the data bus will be ~70 ohms4. Since I = V/R, I ~ 70 mA in our data bus. This current means that a wire larger or equal to AWG 30 is needed5. We chose M22759-11-28 for our data bus. For our power purposes we have a 28VDC power line running through our GA. The max power required by our ARM will be ~200 W. Since P = VI, I = 200W/28VDC ~ 7 amps in our power lines. This current means that a wire larger or equal to AWG 18 is needed. We chose M2275911-18 for our power lines. For our video cable we chose NTSC coaxial cable.

BOOM
The requirements that were considered when selecting a boom included the strength needed to capture Hubble and Dexterous Robot, the structural stability (i.e. wont deform due to thermal expansion/contraction), and the weight.

4 5

Electrical_Systems_Notes_UofT2004 by Ross Gillett Electrical_Systems_Notes_UofT2004 by Ross Gillett

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Type of Structure We considered four different types of structures for the GA Boom: a tube, a square prism, an Ibeam, and a truss structure. The tube, square prism, and I-beam were compared using moments of area. The truss could not be compared using this method since it does not have a constant cross-sectional shape and would require Finite Element Analysis for an accurate model, which would increase the complexity of our design. I indicates the resistance to bending about the x-axis. I indicates the resistance to bending about the y-axis. I indicates the resistance to twisting about the center line (x-y intersection).
o xx yy

Table 1 - Properties of Potential Boom Structures


Shape of Cross-Section Circle Square I I
xx

yy

8.15875E-06 6.73333E-06 1.32933E-05

8.15875E-06 6.73333E-06 4.58333E-06


2

1.63175E-05 1.34667E-05 1.78767E-05

Using a cross-sectional area of 0.004m , it was determined that the I-beam has the largest I and I , the Tube has the largest I , and the tube has the second largest I . If there was not such a large discrepancy between the I-beams I and I , it would appear to be the best of the three. However, we think the tube shape is the best of the three for the GA Boom even though the I , and I for the tube are not the largest, they are close.
o xx xx yy o yy o xx

Next, we wanted to compare the tube and the truss structure. The truss structure was statically indeterminate, making it very difficult to analyze analytically. Finite Element Methods could be used to analyze the truss structure, but were not at our disposal. In the end, we decided upon the tube structure for the GA Boom because it was the best of the uniform cross-section shapes, and simple. Whereas, the truss structure was complicated with many weld points and could present a hazard if an HST or HRV component became entwined in the truss structure.

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Material
For our choice of GA Boom material we chose from 4 materials; Aluminum, Steel, Titanium, and Carbon Composite.

Table 2 - Properties of Potential Boom Materials


Material Density (kg/m3)
2700 1600 4850 7850

Youngs Modulus E11 (GPa)


7.31E+10 2.03E+11 1.02E+11 2.03E+11

Youngs Modulus E22 transverse (GPa)


7.31E+10 1.12E+10 1.02E+11 2.03E+11

Thermal Coef.
6

Aluminum Carbon Fibre Titanium Steel AISI C1020

(x10 K ) 23 0.6-4.3 8-10 10-18

-1

From this data it is clear that carbon fibre has the lowest density, lowest thermal coefficient and one of the strongest longitudinal Youngs Moduli. The only setback for carbon fibre is that the transverse Youngs Modulus is quite weak. However, since the carbon fibre has a low density multiple layers at different angles may be used to nullify the problem of the low transverse Youngs Modulus. In the end, we chose carbon fibre as the GA boom material since it would provide the lightest structure, smallest error due to bending and thermal expansion.

Number and Length of Booms


The requirements used in considering the length and number of booms on the GA included determining that Hubbles Grapple Fixtures is approximately 22ft from its base and the GA must reach over the DM from the edge of EM cargo bay where it is stored. Based on these requirements as well as the assumptions made in the Worst Case Capture Scenarios from above, it was determined that the total length of the GA had to be at least 32ft (~10m). A single boom of 10m would not be able to reach the entire work area once the HRV is stationed, so a single boom could not be used. Two booms would be able to reach the entire work area once the HRV is stationed, as long as the two booms are of equal length (~5m). A structure of three booms is excessive since it adds complexity to the structure with additional joints and necessary position computation. In addition, the added dexterity of the three booms is not necessary since the work areas are all reachable through generally direct paths. Thus, we chose to use two booms of 5m on the GA, since two booms keeps the complexity at a minimum while providing the reach and dexterity to perform all of its tasks.

Final Boom Configuration We selected carbon fibre for our boom material. Carbon fibres low density, large Youngs modulus, and low thermal coefficient make it the optimal choice for a boom to be used for outerspace applications.

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Our final boom configuration consists of two hollow cylindrical booms, each 5.5m in length, and a smaller boom before the EE that is 0.3 m in length. Each boom has an outer diameter of 20cm and a wall thickness of 5mm. (Appendix B: GA Boom Analysis)

JOINTS
Joint Selection
In large part, the choices available in selecting joints are limited by the earlier choice made regarding boom selection, specifically the number of booms. By choosing a two-boom plus wrist configuration the GA begins to resemble the Canada Arm. Given this, the motivation for choosing joints is to mimic and improve the function of a human arm. The most obvious choices are elbow/hinge like revolute joints, and wrist like spherical or ball joints, with prismatic and cylindrical joints also as options. Prismatic joints are relatively simple in that they have only one translational DOF. A translational DOF is not an obvious choice for a robotic manipulator like the GA, but it could potentially offer an extra degree of freedom to provide greater reach. However, a reach advantage is not necessary if the GA dimensions are chosen to ensure that all areas of the workspace are within reach. Thus, prismatic joints are not considered any further. Cylindrical joints provide two DOF, one translational and one rotational, making them slightly more complex than a pure translational joint. However, as discussed in the previous paragraph, a translation degree of freedom is unnecessary for the GA. The allure of a cylindrical joint is the rotational DOF, but the added complexity of the translational DOF makes the cylindrical joint a poor choice for the GA. The two most common joints with only rotational degrees of freedom are those that most resemble the joints of a human arm. A revolute joint provides a single rotational DOF while a spherical joint provides three rotational DOF. Both are acceptable choices for the GA, but the choice of one over the other or a combination of the two is dictated by the configuration of the joints on the arm. In particular, the design requirements stipulate a robotic manipulator with six DOF total. The arrangement of these DOF must be chosen such that the GA can reach all points in the workspace. There are several ways to arrange the necessary DOF, though some DOF must necessarily be located at a given point on the GA. For one, to achieve the requirement of grappling the HST and maneuvering the DR within the workspace, the GA must have sufficient DOF at its wrist. Pitch and yaw DOF are most essential for positioning the DR, while roll DOF is essential for aligning with the HST and DR GF. The remaining DOF are used for the crude positioning of the GA in the workspace. To achieve side-to-side motion, the most obvious choice is to put a joint with yaw DOF at the shoulder. A pitch and roll joint could be used at the elbow to somewhat mimic this side-to-side motion, or at least to cover the same area as a yaw joint at the shoulder. However, this would put two joints at

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the elbow and only one at the shoulder. While there is nothing obviously wrong with this in terms of DOF, it does mean that there is more weight at the elbow than necessary. This translates into the need for a stronger and possibly heavier structure for the booms. Thus, the fourth DOF is achieved using a yaw joint at the shoulder. This leaves only pitch maneuvering, in particular at the elbow. But to achieve full reach in the pitch plane a DOF in pitch is also required at the shoulder. The use of a pitch and roll joint at the elbow could have eliminated the need for a pitch joint at the shoulder, but again it is more desirable to concentrate weight at the shoulder rather than the elbow. This results in a final configuration of pitch and yaw joints at the shoulder, a pitch joint at the elbow and a pitch, roll and yaw joint at the wrist. Based on this configuration the choice of the type of joint to use at each arm joint can be made. It is only at the wrist where three DOF are required, so using a spherical joint at this location is a possibility. A spherical joint is essentially a ball and socket joint. The clear advantage of a spherical joint is that it has three DOF built in. However, this also is a draw back of the joint, in that it is more difficult to control three DOF than one. Ease of control is essential in achieving the required precision for the GA. Precision also depends on actuation method and control system configuration, which will both be discussed in the next section, but the difficulties associated with control of a three DOF spherical joint make it a less desirable choice for the GA. This leaves only revolute joints. A revolute joint has only one DOF, so to implement revolute joints for the GA there will need to be two revolute joints at the shoulder, one at the elbow and three at the wrist. Using three revolute joints rather than one spherical joint does add weight far from the pivot point, but the driving requirement in selecting joints is precision not mass.

Actuation
Along with the type of joint, the method of joint actuation is essential in achieving the required precision. Also, the actuator must be able to handle the torques applied during HST capture and loads during the DR servicing mission. There are a few common choices for joint motors, namely stepper motors or dc servomotors (dc brush and brushless). Of the three choices, DC brush motors are by far the simplest. They can be used in both open and closed loop configurations and they do not require an electronic driver to operate. However, this simplicity is not enough to outweigh the major disadvantage of a brush motor, which is having a lifetime on the order of 50-200 hours in a vacuum. This is a very short lifetime and given the nature of this project, simplicity of design is not a major concern. Thus, DC brush motors are not a good choice for GA joint actuation. DC brushless motors are significantly more complex than their brush counterparts. They can also be used in either open or closed loop configurations, but their greatest advantages arise when operated in a closed loop, most often with position feedback. When combined with good sensors, these motors can provide extremely precise position control. It is possible to find encoders (sensors) with on the order of 100,000 pulses per revolution. In fact, the precision of a brushless DC motor is governed more by the quality of the sensors than the motor itself. DC brushless 29

motors are also significantly more efficient than stepper motors (which will be discussed later) as a result of the commutation process. They also can provide up to 2-4 times the power of a similarly sized stepper motor. The primary disadvantage of DC brushless motors is that they are considerably more complex than the alternatives, and thus are more costly. Stepper motors are also a potentially good choice for GA joint actuation. Steppers are primarily open loop devices, but they can achieve fairly accurate positioning even in this configuration. The limitation of stepper precision is governed by the step size, and the degree to which micro stepping is possible. For a typical four-phase stepper, micro steps are in the range of 25000. The incremental step sizes however result in accelerations and decelerations, which lead to inefficiencies in the motor and thus high power consumption. Though a stepper motor would be a fair choice for this application, they are simply not as precise as DC brushless motors. The precision requirement is the driving factor in choosing both the type of joint and the method of actuation. Thus, the best choice of motor for this application is a DC brushless motor. They are the most precise of the three potential choices and are also very efficient.

Material
The main restrictions affecting the type of material used for the joints are: - Tight projected mission schedule (must launch in 2008) - The joint must be able to repeatedly and consistently move in an accurate, predictable manner - The joint should last at least the life-time of the mission (say at least 5 years to get a safety margin) The limitations on materials that can be derived from above requirements are: - Since the mission is soon up-coming, should use tried-and-true technology rather than experimental materials - Structure: The joint must be strong/tough to sustain repetitive movement (should not wear out quickly) - Structure: The joint should not rust, decay or build up deposits which could hinder its movement In terms of materials, there are the typical materials used for many previous space applications including stainless steel, aluminum, titanium, and carbon composites. Other newer or more exotic materials examined include carbon-carbon machineable composites, metal matrix composites, beryllium and alloys, and invar. The pros and cons for each material are summarized in Table 3. The material chosen for the joint was titanium. Since the requirements specified that time is a restraint, it was decided that typical materials should be used since they have been proven space worthy. Although aluminum and stainless steel are less expensive than titanium, they are more likely to corrode or deform, which would affect joint motion. Carbon composite is more of a material for the booms being stiff and

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light. Since the joint is constantly moving, some flexibility would be beneficial. Thus, titanium was chosen because it is strong, highly resistant to corrosion and light.

Table 3 - Benefits and drawbacks of some prospective materials:


Materials Typical Materials
Stainless steel 300 series, 15-5 PH and 17-7, Custom 455 Aluminum 7075 and 6061

Pros
These austenitic stainless steels are frequently immune to general corrosion 6 Favorable strength-to-weight ratios make them the structural metal of choice for aerospace applications. They also can have excellent atmospheric corrosion capabilities. Very strong, highly resistant to corrosion, light7 Most often used to make stiff, light members of regular cross, section. (Examples include robotic booms and supports for solar arrays and panels.)8

Cons
May experience pitting and crevice corrosion and undergo stress corrosion cracking in some environments Protective properties of the aluminum oxide films that form on these alloys can break down locally and allow extensive corrosion. It frequently occurs at bolt and rivet holes or at cutouts where the small grain boundaries perpendicular to the metal surface are exposed. its limited use means that small-scale production operations result in a relatively expensive metal Much more expensive than metal alloys.

Titauium Ti6Al4V Carbon composite

Newer Materials
Carbon-carbon machinable composites Current projects include structural skins for an all carbon thermal protection system for space vehicles. Oxidation resistant coatings available.9

Introducing new materials into a design can be a significant cost and schedule driver and introduces risk.
Degradation that carbon-carbon composites are susceptible to are not detectable at an early stage by traditional non-destructive testing techniques. Once significant damage has occurred to the material, fracture toughness may have decreased dramatically. 10 Relatively difficult to manufacture, inspect, and scale-up. To do all that would be very costly. Poor ductility and fracture toughness. Costly

Metal matrix composites Beryllium and alloys Invar

Near-zero coefficient of thermal expansion, high-temperature capability, high thermal conductivity, and high specific stiffness and strength11 High stiffness, light weight, dimensional stability over a wide temperature range. 12 Very low thermal co-efficient of expansion.

6 http://corrosion.ksc.nasa.gov/html/corr_control_matsel.htm 7 http://www.titan-japan.com/ohanashi/ohanashe.htm 8 Spacecraft Design Course Notes: Mechanical Elements of Spacecraft Design 9 http://www.southernresearch.org/pls/portal/url/page/PUB_ENGINEERING/PROCESS_MANU
10 http://www.southernresearch.org/pls/portal/url/page/PUB_ENGINEERING/PROCESS_MANU 11 http://www.tms.org/pubs/journals/JOM/0104/Rawal-0104.html 12 http://www.wordiq.com/definition/Beryllium

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Joint Motor and Gearboxes The joint motor and gearboxes chosen for our GA was from Maxon Motors (Table 4). Our gear ratio with this motor was determined to be ~ 13,900:1. This was found by dividing our highest torque requirement by the Maximum Continuous Torque of this motor. We decided to use this motor because the maximum power consumption was within an acceptable range, maximum of 12Watts. Also, Maxon is a proven company for electric motors for space applications. N = Torque Required/ (Torque Available*Maximum Efficiency) = 94.7 Nm / (9.86mNm*0.69) = 13,919.51
*94.7Nm was derived from Appendix B: Torque Calculations

In order to reduce the speed of this motor from 5000RPM to our performance required speed of ~0.3075RPM and to increase the torque from 9.86mNm to 94.7Nm, three gearboxes were chosen (Table 4). These gearboxes will be placed in series in order to take full advantage of their performance.

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Torque Calculation
Stage 1 Motor Torque * Motor Efficiency * Gearbox 3.7:1 * Gearbox Efficiency = 9.86E-03 Nm x 0.69 x 3.7 x 0.8 = 0.02014 Nm This satisfies the maximum amount of torque the 3.7:1 gearbox can handle, which is 0.75Nm. Stage 2 Torque @ Stage1 * Gearbox 100:1 * Gearbox Efficiency = 0.02014 Nm x 100 x 0.7 = 1.4098Nm This satisfies the maximum amount of torque the 100:1 gearbox can handle, which is 50Nm. Stage 3 Torque @ Stage2 * Gearbox 93:1 * Gearbox Efficiency = 1.4098 Nm x 93 x 0.7 = 91.8Nm This satisfies the maximum amount of torque the 100:1 gearbox can handle, which is 120Nm.

Speed Calculation
Stage 1 Motor Speed / (Gearbox 3.7:1 * Gearbox Efficiency) = 5000RPM / (3.7*0.8) = 1689.19 RPM Stage 2 Speed @ Stage 1 / (Gearbox 100:1 * Gearbox Efficiency) = 1689.19 RPM / (100*0.7) = 24.13 RPM Stage 3 Speed @ Stage 2 / (Gearbox 93:1 * Gearbox Efficiency) = 24.13 RPM / (93*0.7) = 0.37 RPM Even though the torque and speed do not exactly match the requirements, the speed can be lowered to increase the torque. According to the data and speed versus torque curve [1] provided by Maxon, the highest speed the motor can be run at is 5000RPM with a torque of 9.86mNm. This speed should be avoided during actual operations to ensure long-life cycle of the motor. The curve also shows that running at a lower RPM, approximately 4000RPM for example, the torque value can be increased slightly to just under 10mNm.

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Table 4 Motor and Gearbox values


(Please See Appendix B: Reference# 1,2,3,4 for further details)

Gearbox Part # 166155 -Ratio 3.7 to 1 Part# 110505 - Ratio 100 to 1 Part # 110412 - Ratio 93 to 1

Recommended Input Speed (RPM) <6000 <3000 <3000

Max. Continuous Torque (Nm) 0.75 50 120 Max. Continuous Torque (mNm) @ 5000RPM 9.86

Max. Efficiency (%) 80 70 70

Mass Inertia (gcm2) 1.5

Joint Motor Part #283839

Max Power (W) 12

Max. Efficiency (%) 69

Rotor Inertia (gcm2) 2.2

FINAL JOINT SELECTION


There will be six joints all together on the GA (Fig 1). A yaw and pitch joint at the shoulder, a yaw joint at the shoulder, and a yaw, pitch and roll joint at the wrist. From our trade study in previous assignments, the best joint material to use for the joints will be Titanium. Main Boom Joints (x6) Shoulder Joint Dimensions:
(x2) Main Boom - 5m Length, 20cm Diameter (x6) Joint 20cm Diameter, 22cm height End Effector 40cm OD, 30cm ID, 20cm Length Joint Boom 30cm Length, 20cm Diameter Shoulder Joint 30cm Length, 20cm Diameter

End Effector

Joint Boom

Fig. 1 - GA Stowed Position (Illustration Not to Scale)

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The specified dimensions of each joint, Diameter = 20cm and Height of 22 cm, will be able to accommodate the combined dimensions of the motor and gearboxes provided by Maxon [Appendix B: Reference #1, 2, 3, 4], which is approximately 8.1cm Diameter and 21cm in length. The joint boom is to provide structural reinforcement between the End Effector and wrist joint. This additional joint will help relieve torsional and shearing stresses on the wrist joints by having a slightly higher wall thickness.

ELECTRONIC COMPONENT CASINGS


For the eight circuit boards distributed throughout the GA, the components outlined from our EFBD in the previous assignment will be enclosed in Aluminum Casings. Since there are no structural stresses, the wall thickness can be made extremely small similar to a computer case. With a volume of 15cm x 15cm x 30cm, a thickness of 2mm, and a density of 2700 kg/m3, the mass of each casing is approximately 0.60kg by using the formula Mass = Density x Volume.

THERMAL/ENVIRONMENTAL CONTROL
The purpose of having thermal controls is to maintain the electronics and mechanical parts within its designed operational temperature range and to minimize energy loss. There must be a sufficient amount of thermal control material to keep the interior components from melting or internal malfunctions (i.e. the casing, motors, electronics.) Just as an idea for the allowable temperature ranges, electronics should be operated within -200C to 650C. Table 5 describes the trade-offs between each type of thermal control.

Table 5 - Types of thermal controls available


Type Passive Control
Phase change device Thermal blankets or other insulation Gold blanket

Pros
Useful for electrical equipment that experiences short power spikes. Lighter and less expensive than conventional tiles The outer layer of the blanket is a type of second surface mirror material with high reflectivity and high emissivity. On the sun side, the sun reduces static charge buildup because of photoemission of electrons from the Kapton. Same as gold except for outer layer which has a higher absorptivity and lower emissivity than the gold Kapton outer

Cons Less dynamic, less controlled


Unable to absorb any more heat after melting, allowing temperature to increase thereafter. Will radiate some heat to space but their insulating properties increase with the number of layers.13

Black blanket

13 http://www.qrg.northwestern.edu/projects/vss/docs/thermal/3-what-materials-are-used-for-thermal-control.html

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Paints or coatings Radiators

layer, to cut down on radiation of spacecraft heat to space. This layer is also electrically conductive. By grounding the outer layer to the spacecraft frame the static charge buildup which occurs on the anti-Sunside is dissipated. 14 Thermal coatings are very efficient and lightweight. i.e. Teflon coating has a high emissivity and radiates heat to space. 15 Generally much simpler than active radiators and easily mass produced

Coating will degrade over time. Radiators in space have to be much larger than that on earth to perform the same cooling16

Active Control
Heaters Fluid loops Air coolant loop Water coolant Freon coolant Heat exchangers

More complex, needs additional moderation


Electrical heaters are used for fine temperature control, and usually only for short periods of time. Lower heat transfer rate Lower heat transfer rate Lowest operation temperature of the three.
17

Louvers

Highly conductive heat path and extremely high heat transfer rates. Lightweight, can be used for a wide range of temperature, and can have variable conductance. A controlled rate of heat dissipation.

Slow inert gasses can be generated18

High temperatures can occur if they are pointed at the sun.

14 http://www.qrg.northwestern.edu/projects/vss/docs/thermal/3-what-materials-are-used-for-thermal-control.html 15 http://www.qrg.northwestern.edu/projects/vss/docs/thermal/3-what-materials-are-used-for-thermal-control.html 16 http://www.permanent.com/i-heat-x.htm 17 http://www.tsgc.utexas.edu/archive/subsystems/thermal.pdf 18 http://www.tsgc.utexas.edu/archive/subsystems/thermal.pdf

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Passive Control This includes multi-layer insulation or thermal blankets and radiators. The insulation shields the arm from the cold vacuum of space and radiators on the joints to allow heat to dissipate from motors and electronics when in use.

Thermal Blankets / Multilayer Insulation (MLI) This type of insulation is made of thin layers of metallic foils separated by insulating oxides or fabric in vacuum. Heat transfer across this material is primarily by thermal radiation from one layer to the next. The performance of MLI depends heavily on the details of its configuration. Seams, attaching points, and folds are all paths for heat leakage through the insulation. The effective emittance of MLI typically ranges from 0.002 to 0.02 depending on the area insulated. Like the current Canadarm, the MLI will consist of alternating layers of godized Kapton, Dacron scrim cloth and a Beta cloth outer coating (fireproof). The outer layer of the MLI consists of a 0.001 inch Kapton layer, which acts as a type of second surface mirror material with high reflectivity and high emissivity. The multiple layers within the blanket are 0.00025 inch Kapton thin silver coating on each side. These layers are separated by a Dacron netting, which prevents contact of the adjacent silver layers. The inside blanket layer makes contact with the spacecraft body. The blanket layers exchange heat between adjacent layers by radiation. Surface area of booms = surface area of blankets = (10.5m x pi * 0.2m) x 2 booms = 13.2 m2 Thickness of blanket = 2.5 mm = 0.0025 m

(http://www.tsgc.utexas.edu/archive/design/phobos/)
Volume of blanket = 0.0025 x 13.2 = 0.033m3 = 33000 cm3 Density = 1.42 g/mL=1.42 g/ cm3 Mass of blankets = 46860g = 46.8 kg

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Radiators There will be a radiator located at on the surface of each joint, with a 10cmx10cm surface area. The radiators are made of aluminum, and have a silver Teflon surface coating. This material is referred to as a second surface mirror. The material consists of a 0.010inch layer of transparent Teflon coated with a thin layer of silver and a protective layer of Inconel. The material is applied to the space side of the aluminum plate. The grapple arms internal heat is conducted to the inside of the radiator plate via a conductive gold foil connected to mechanisms that produce a high heat. The Teflon has a high emissivity and radiates the heat to space. In addition, the sunlight may strike the first Teflon surface, pass through to the second silver layer, and be reflected back to space. This will protect heat from getting into the GA. Radiator thickness = 0.5 cm = 0.005m Radiator surface area = 100 cm2 = 0.01m2 Volume of radiator = 5x10-5m3 Density of aluminum = 2700 kg/m3 Mass of radiator (each) = 0.135 kg Total mass of radiators = 0.135 x 6 = 0.81 kg Emissivity of 5 mil Silvered Teflon = 0.78 Absorptivity of 5 mil Silvered Teflon = 0.05 to 0.09

(http://www-personal.engin.umich.edu/~adoolin/index_files/ thermal%20management%20problem%202b.doc) Assume highest operating ambient temperature = 20 deg C = 293 K Energy radiated to space = A(T4s T4a) = 0.01 m2 * 5.67x10-8 W/m2/K4 * 0.78 (3^4 273^4 )
= -3.26 W

Energy absorbed from space when directly exposed to solar radiation = GA = 1358 Watts/m^2 * 0.09 * 0.01 m2 = 1.22 W
(Refer to Appendix B: Heat Transfer for derivation of equations)

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Active Control This type of thermal control would involve some sort of mechanical and electrical action. In the GAs thermal control system, the only active components are sets of thermal control loop consisting of a thermostat and flexible heaters. If the thermostat dips below a certain range, the heaters will be activated to drive the temperature back to acceptable values. These heaters will be placed on each circuit board. The distributed architecture for the active thermal control units (thermostat and heater) is described in the EFBD. There are 2 sets for these units (for redundancy) in each joint, 2 for the snare motor, and 1 each for the elbows 2 pan-and-tilt camera and motors. It was determined that active controls that required fluid flow (such as fluid loops, heat exchangers) were impractical since there is nowhere for the fluid to flow to (unless through the booms to other joints) and it would increase the weight of the arm significantly.

LUBRICANTS
The requirements stress that lubricants should have a long-life performance to meet the mission demands. The main types of lubricants were examined, liquids, greases, and solids. Again, although the new lubricants were briefly examined, it was deemed that tried-and-true methods were a safer choice. The major drawback in using a liquid lubricant is that the lubricant can be lost through vaporization, creep or inadequate supply. Though countermeasures can be used they may be unfeasible due to the small size of the joint. For example, to ensure adequate lubricant supply, positive feed systems can be developed to control the flow to certain areas, but that would require a reservoir of lubricant and more complexity, thus liquid was not chosen. Typically, films are used only when it is not possible to use liquid or grease. The major drawback in using a solid lubricant is that since films have finite lives, they should not be used for rolling-element bearing applications that would experience more than a million cycles of sliding. Thus solid films were not chosen, unless in combination with a grease lubricant. Grease lubricant is already used in a variety of space applications, such as ball bearings, journal bearings and gears. The reason grease is so favored is that the grease can act as a reservoir for supplying oil to contacting surfaces. It also acts as a barrier to prevent oil loss by creep or centrifugal forces. Thus, grease lubricants were chosen for the joints.

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JOINT SENSORS POSITION, VELOCITY, FORCE


Internal state sensors are devices to measure the position, velocity and acceleration of robotic joints by providing a feedback for the robots position and motion control system. Only sensors for revolute joints were considered since the grapple arms joints are revolute. A set of sensors was chosen to measure different performance parameters in the joint as well as to add redundancy where possible. Limit switches were chosen to determine whether a joint had reached its limit of travel (i.e. rotated 360 degrees). For odometry, the most common and wellknown position sensor is the optical encoder. An absolute optical encoder will be used, rather than an incremental one, due to its higher quality and resolution. For angular velocity and position, the syncro and resolver was chosen over tachometers due to the accurate output and less noise in the signal. For force/torque, a senor based on strain gauges will be used. The strain gauge element will be chosen such that its resistance change is linear over the operating force range.

Table 6 - Benefits and drawbacks of various internal sensors


Sensor type Position
Limit switches Potentiometers Optical encoders (absolute and incremental) Absolute Optical Encoders Incremental Optical Encoders

Pros
Simplest type of sensor for binary conditions (i.e. reach limit of travel) Inexpensive Long life, the most common Absolute position is always known. Typically higher quality and resolution may be increased with multiple rings Simpler and more common than absolute encoder Inexpensive Extremely accurate output for a reasonable cost. Can determine both rotational position and velocity, thus can be used for both odometry and velocity tracking. 20

Cons

Only measures accuracy to 0.5% Limited life due to physical wiper contact wear Sensitive to shock More expensive than incremental Must be calibrated when first powered up. Output is noisy and has limited life due to commutator brush wear. 19 Requires an analog to digital converter

Angular velocity
Tachometers Synchros and resolvers

Torque/Force
Servo accelerometer Strain gauges Requires servo motor (active part) Most common basic element for force sensor

19 http://scholar.lib.vt.edu/theses/available/etd-7698-132910/unrestricted/Chapter2.pdf 20 http://me.queensu.ca/courses/MECH497/CD/htmlmods/robot/SENSORSS.htm

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END EFFECTORS
Type There are two main types of end effectors that can be used. The first utilizes specially shaped grippers to grab onto the target (Fig. 2) and the second utilizes wire ropes to snare the target (Fig. 3). The end effectors with specially shaped grippers are used in tasks that are small and complex in nature. They are designed to interface with specific grapple fixtures and perform specific tasks. These types of effectors can be seen on the arms of the SPDM, where it must connect with many different interfaces in its dexterous tasks and performing services such as attaching tools, activate fasteners, slide doors, turn bolts, etc Due to the nature of the tasks, this type of end effector is much smaller in comparison to the wire rope end effectors. The gripping forces and misalignment tolerances are also much smaller. This is necessary because a missed grasp or an excessive amount of force by the grippers can damage the target interface as well as its own components such as the Socket (Appendix B: Reference #5). The wire rope end effectors are typically used when there is a large tolerance for misalignments and when a large amount of force is required to hold the target in place. These types of end effectors are can be seen on large maneuvering objects such as Canada Arm 2 where it uses the effectors to attach itself to the Space Station and other large objects like a Shuttle. Since these types of effectors can absorb large amounts of force, they are required to be quite large in size. This large size along with its wire rope configuration limits the amount of fixtures it can interface with. Henceforth, the tasks performed by these types of end effectors must remain simple. It should only interface with fixtures such as power and data, and connections that attach a payload where it is directed appropriately (Appendix B: Reference #5). Therefore, with its high strength and limited capabilities this type of end effector is most suitable for attaching the Dexterous Robot or the Hubble Space Telescope onto the Grapple Arm, which satisfies the functional requirement of being able to connect to either the DR or HST as well as the requirement of having a large capture envelop in case of HRV tracking errors and HST rolling. The yellow-coloured rectangular shaped objects on the outside of the cylinder in Figure 3 are the power and data connections to the DR, which satisfies the functional requirement of providing power to the DR.

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Fig. 2 Gripper Type End Effector

Fig. 3 Snare Type End Effector

Force/Torque Sensors Force sensors are typically strain gauges attached to the surface of the object being measured (Fig. 4). A strain gauge essentially converts mechanical motion into an electronic signal. The deformation or strain that occurs in an object being stressed causes a change in capacitance, inductance, or resistance. This change is proportional to the strain being experienced by the sensor and therefore, the amount of force being applied can be measured. An electrical strain gauge is however, subject to instability and inaccuracies due to temperature, material properties, the adhesive that bonds the gage to the surface, and electromagnetic interference. However, it has been tried-tested-and-true over the past, and therefore should be used to reduce additional research and development complexities. Fibre optic force sensors are another method of measuring force. It uses reflected light from a fibre optic probe to measure the force. There are no electrical signals and/or attachments. This allows for much greater precision and accuracy when compared to an electrical strain gauge (Appendix B: Reference #6). However, fibre optic cables are subject to deterioration due to radiation. Therefore, this type of force sensor should not be used.

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Fig. 4 Strain Gauge

Material The materials that should be considered for use on the end effector include Titanium, Beryllium, and Aluminum. Titanium has higher then average fracture toughness compared to Beryllium and Aluminum, it is light in weight, has high boiling and melting points, but its stiffness is only average and is a more expensive material. Beryllium has higher then average stiffness, light in weight, higher thermal conductivity then Titanium, and is stable over a wide temperature range. On the other hand, it has poor ductility and fracture toughness. Aluminum has a good strength to weight ratio, corrosion resistance, widely available, the highest thermal conductivity, relatively cheap compared to Titanium and Beryllium, but it does not have fracture toughness as high as Beryllium or stiffness as high as Titanium and it has relatively low melting and boiling points (Appendix B: Reference #7). For end effectors, stiffness is an important factor, but a material that is too stiff tends to have low fracture toughness such as Beryllium. If the GA were to misalign and hit the DR, it would be undesirable for the material to fracture during the impact. Since the component must also maintain a certain position for long periods of time, must have dimensional stability and not deform due to fatigue, thermal expansion or contraction, etc Titanium is the optimal choice for an end effector. It offers much more benefits compared to Aluminum and Beryllium. In the near future, Titanium may not be the optimal choice for space applications. Metallic Matrix Composites (MMC) is currently being researched and developed. These are types of composites that include continuous-fibre reinforced boron/aluminum (B/Al), graphite/ aluminum (Gr/Al), and graphite/ magnesium. They are beneficial to space applications due to the fact that it can operate at very high temperature, has a near-zero coefficient of thermal expansion, good thermal conductivity, high strength and toughness, lightweight, and have dimensional stability in the presence of dynamic and thermal disturbances. They are also resistant to micro-fractures due thermal cycles and radiation exposure, and electromagnetic interference. Currently, MMC is quite expensive due to the limited manufacturing processes available (Appendix B: Reference #8).

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Final Design The EE will be made from Titanium as indicated by the trade study completed above. The dimensions will be: 40cm (OD), 37cm (ID), and 40cm Length providing a mass of 35kg. These numbers were determined by taken into consideration the size of the Grapple Fixtures on the HST as well as the amount of stress experienced by the EE. The EE will have two cameras, two LED lights, and two Laser Rangefinders. Only one of each component will be operational at any given time, the others will be redundant systems. However, if a wider field of view is required for capture of HST or DR, the other vision systems may be used as well. The Power and Data connections will be done by using motorized prongs (Fig. 5). These prongs will be extended by the same motor and gearbox combination will be the as above due to the fact that a slow speed is required to prevent damage when inserting the plugs into DR as well as to reduce the need for having to design an alternate motor/gearbox combination. This would be time saving and cost effective.

Camera Power and Data Connection

Motor and Gearbox combination

LED Light

Laser Rangefinder

Fig. 5 End Effector (Illustrations Not to Scale)

44

SNARE MOTOR AND GEARBOX SELECTION


The snare motor and gearboxes chosen for our End Effector was similar to the above joint motor and gearbox selection. We used Maxon Motors (Table 7) for our DC Brushless Motor and Direct Industry Ltd for our gearboxes. We used a different company for our gearboxes because Maxon only provides gearboxes up to 120Nm and we require a torque of 158.4Nm. Our gear ratio with this motor was determined to be ~ 3393:1. This was found by dividing our highest torque requirement by the Maximum Continuous Torque of this motor. N = Torque Required/ (Torque Available*Maximum Efficiency) = 158.4 Nm / (60*0.776) = 3393
*158.4 Nm was derived from Appendix B: Torque Calculations

In order to reduce the speed of this motor from 4000RPM to our performance required speed of ~1.8RPM and to increase the torque from 60mNm to 158.4Nm, two gearboxes were chosen (Table 7). These gearboxes will be placed in series in order to take full advantage of their performance.

Torque Calculation
Stage 1 Motor Torque * Motor Efficiency * Gearbox 35:1 * Gearbox Efficiency = 60E-03 Nm x 0.776 x 35 x 0.965 = 1.57 Nm This satisfies the maximum amount of torque the 35:1 gearbox can handle, which is between 42Nm-485Nm [1]. Stage 2 Torque @ Stage1 * Gearbox 100:1 * Gearbox Efficiency = 1.57 Nm x 100 x 0.965 = 152Nm This satisfies the maximum amount of torque the 100:1 gearbox can handle, which is also between 42Nm-485Nm [1]

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Speed Calculation
Stage 1 Motor Speed / (Gearbox 35:1 * Gearbox Efficiency) = 4000RPM / (35*0.965) = 120 RPM The input speed of the motor satisfies the highest speed the gearbox can handle, which is 4500rpm. Stage 2 Speed @ Stage 1 / (Gearbox 100:1 * Gearbox Efficiency) = 120RPM / (100*0.965) = 1.25 RPM Even though the torque and speed do not exactly match the requirements, the required speed calculated is assumed to be under worst-case conditions.

Table 7 Snare Motor and Gearbox values


Mass Inertia (gcm2) 70

Gearbox (Direct Industry) Part # SP060 -Ratio 35 to 1 Part# SP060- Ratio 100 to 1

Recommended Input Speed (RPM) <4500 <4500

Max. Continuous Torque (Nm) 485 485

Max. Efficiency (%) 96.5 96.5

Joint Motor (Maxon) Part #200142

Max Power (W) 30

Max. Continuous Torque (mNm) @ 5000RPM 53.8

Max. Efficiency (%) 77.6

Rotor Inertia (gcm2) 92.25

(Please See Appendix B: Reference #9, 12 for further details)

VISION SYSTEMS
Vision systems on the GA should include cameras at the tip of the End Effector, LED Lights, and a Laser Ranging system. The types of camera that could be used include an externally mounted camera with many degrees of freedom or an internally mounted camera that is fixed in place. For an internal camera placed at the tip of the end effector, it will have limited movement and would add complexity to system due to the fact that it will be required to be small in nature. The camera must also be pointed in one direction meaning that movement is restricted and would

46

hinder the field of view. This can be corrected with the use of a fish-eyed lens. The microprocessors can orient, select, and correct the field of view. It can also pan, tilt, rotate, zoom, and triangulate distances without moving parts. Using a fished eyed lens on this camera rather than a conventional lens generates a wider field of view without additional cameras. Due to the lens hemispherical shape, it can provide up to four simultaneous views. The microprocessors and its software would then translate the hemispherical fields of view back into regular 3D views that an operator would understand (Appendix B: Reference#10). This internal camera should be placed directly at the end effectors tip in order to provide the maximum field of view and the most accurate distance triangulation. However, the processing power required to translate the hemispherical views back into views that the operator can understand would be high. Therefore, an ordinary lens should be used on the end effector camera. This would reduce complexity and the cameras to be located on the booms would provide the wide field of view required for capture. Externally mounted cameras on the booms are also required. Mounted on one of the booms of the GA, an external camera would be able to view all areas of space except for areas right underneath the GA. To solve this problem, a second camera should be placed on the opposite side of the boom. However, for externally mounted cameras, it cannot be mounted directly onto the end effector or even close to it. This is due to the fact that there is the possibility of the end effector misaligning with the DR during capture and the cameras could be damaged and/or ripped off of the GA. Therefore, the GA will have two externally mounted, fixed-view cameras on the End Effector as well as two externally mounted cameras with pan, zoom, and tilt on the booms. Laser Radar uses light waves to detect and range find objects. It is similar to conventional radar only it doesnt use radio waves (Appendix B: Reference#11). LIDAR can be used to measure speed, distance, rotation, chemical composition and concentration. The main advantage of laser radar is that it can measure or produce an image of an object that is as small as the size of the lasers wavelength, which is about 600-1550nm. In contrast, radars radio wavelengths are center meter sized meaning that objects smaller than a coffee cup would be difficult to see on radar without a large power boost. Furthermore, radars require reflective surfaces such as metallic surfaces in order to capture a good image. Hence, for non-metallic surfaces, radars produce a weak and distorted image or it may not be able to produce an image at all. On a LIDAR system, the wavelengths are so small that they are often used for making measurements of smoke and other airborne particles (Appendix B: Reference#11). However, LIDAR requires much greater computer power to process the high resolution images then radar. Because of this, it is also difficult to spread out a laser beam to perform searches in a wide region, whereas conventional radar can easily create a wide beam and narrow it down for accuracy. There is also the problem that HST is highly reflective and thus not would provide an accurate image. A laser range finder should also be included and placed near the camera on the end effector. This would assist in approximating the distance to the DR and HST when the operator is attempting to capture.

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TIE DOWNS SELECTION


There were five main characteristics for the GA tie downs that we had to decide on: type/release mechanism, number of tie downs, location of tie downs, material, and position of GA for tie down. Type/Release Mechanism We looked at 4 ideas for the GA tie downs for securing the GA during launch and transport: Pin and Socket - A pin slides in and out of the guiding sockets

Latching Hook A hook is latched on to a catch on the GA

Belt A belt is tightened on the GA before take off

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Molded Absorbers molds hold the GA in place and are mechanically removed to free the arm.

Absorbers placed underneath the GA will prevent damage during launch and proximity operations due to the vibration and movement that will occur (Fig. 6, Fig. 7). The Pin Release Mechanism will be inserted or removed by a rack and pinion gear. It will be powered by the same motor and gearbox combination as the joints due to the fact that high speed is not necessary and this would eliminate the need for an alternative motor/gearbox design. The pin will be inserted underneath a lobe attached to five different areas of the GA (Fig. 6, Fig. 7). These absorbers will be made from Aluminum for lightweight, corrosion resistance, and strength. To reduce the friction caused between the absorbers, the booms and End Effector, the Aluminum absorbers will have a Teflon coating that will act like a lubricant to allow small amounts of sliding. The absorber attached to the End Effector will have a height slightly greater than the others to compensate for the increased height between it and the EM. To decrease weight of the blocks and maintain strength, the blocks can be hollow and have a wall thickness of 2cm. The mass of the block was calculated using the Mass = Density*Volume formula and the results are shown in Table 8.

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Boom Lobe

Pin
(Inserts through lobe)

Gearbox and Motor

Aluminum absorber with Teflon coating

Fig. 6 Absorber and Pin Release Mechanism (Illustrations Not To Scale)

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Location The location of the tie downs depends on the weight of the joints and EE of the GA. We want to place the tie downs in such a way as to maximize the natural frequency and minimize the stress on the arm during transportation. The absorbers are placed to areas that the greatest deflection and bending moments would occur (Fig. 7).

Fig. 7 Locations of Absorbers and Pin Release Mechanisms (Illustrations Not To Scale)

Fig. 8 - Deployed Configuration (Illustrations Not To Scale)

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Table 8 - Mass Budget


Component Laser Rangefinder Resolver Elbow Camera with Pan/Tilt/Zoom Resolver-to-Digital Converter LED Lights Control Unit Aluminium Casing for Control Unit Joint Motor Gearbox Joint, PD Connect, Pin Release Mechanism Part# 110505 - Ratio 100 to 1 Part # 110408 -Ratio 3.7 to 1 Part # 110412 - Ratio 93 to 1 Gearbox Snaring Motor Part # SP060 -Ratio 35 to 1 Part# SP060- Ratio 100 to 1 Main Boom Joint Boom Joint Shoulder Joint End Effector Snaring Motor Cables End Effector Camera Absorption Blocks Pin Release Mechanism with Motor and gearbox Thermal Blankets Radiators Quantity 2 22 2 22 2 8 8 6 Mass of each component (kg) 5.7 3.2 2 Negligible 4.6 <2.8 0.6 0.067 Total Mass (kg) 11.4 70.4 4 9.2 <22.4 4.8 0.402 Reference # 13 14 15 16 17 Formula 1

6 6 6

1.54 2.3 3.7

9.24 13.8 22.2

2 3 4

1 1 2 1 6 1 1 1 1179.5m 2 5 5 0.033m3 6

2.0 2.0 27.8 4.1 4.28 5.8 35 0.088 0.46 2.29 0.067 1.42g/cm3 0.135 Total

2.0 2.0 55.6 4.1 25.7 5.8 35 0.088 10.56 0.92 11.45 0.402 46.8 0.81 346.62

9 9 Appendix GA Appendix GA Formula Formula Formula 12 Table 9 15 Formula 1,2,3,4 18 20

Table 9 - Detailed Cable Mass Budget


Type M22759-11-28 M22759-11-18 NTSC Density 0.002023kg/m 0.01212 kg/m 0.02 kg/m Total Length 535.2m 609.3m 35m Total Weight Reference# 1.08 kg 7.3847 kg 2.09 kg 22 22 21

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Electrical
The design of an electrical system for the GA was hindered by the limited availability of high performance components that have been tested and approved for use in space. The mission requirements could potentially impose specifications on the system that might not be attainable given the current state of the art in space rated technology. However, by implementing telerobotic capture and given the precision requirements derived in the previous section, the electrical architecture outlined in this section meets all the relevant mission requirements.

ELECTRICAL REQUIREMENTS
The following requirements are derived from the NASA mission requirements.

FUNCTIONAL REQUIREMENTS
GA must provide single fault tolerance: including power, data lines, and electronics. GA must provide power and data connections to the DR GA must provide a vision system to aid in capture and servicing tasks

PERFORMANCE REQUIREMENTS
GA must have open loop accuracy of less than 1.5 and 2 at the tip GA must have position repeatability of 0.16 at the tip

ELECTRICAL ARCHITECTURE
The GA implements a distributed electrical architecture with microprocessors at each of the six joints, at the boom cameras and at the end effector, which are bussed back to the GA CPU. The local microprocessors are housed on circuit boards along with other components such as analog to digital converters and motor drivers. The use of a distributed architecture drastically cuts down the number of conductors running along the arm, which is the reason it was chosen. The overall power and data connections for the electrical architecture are shown in the figure below. In order too comply with the single fault tolerance requirement, the electrical system was made almost entirely redundant. There is a primary power line, a secondary power line, a primary main data line, and a secondary main data line. The main data lines are implemented using the MIL-1553 standard. There are also primary and secondary data lines for the DR to EM connection, which are implemented using the RS-422 standard. Finally, the connection between GA and EM is made redundant in the same fashion, and also uses RS-422. The relays to switch between lines are located on the EM and will switch either in response to overcurrent detection or upon command from ground control.

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GA DISTRIBUTED ARCHITECTURE - POWER AND DATA EFBD


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As the figure above shows, each of the local processors is called a Control Unit. The DR Interface Control Unit is simply a circuit board with plugs to interface with the DR grapple fixture. The Control Units are powered in parallel by branching off the main power lines. 18gauge wire was chosen for the power lines based on the 28V power supply and an estimated power of 200W. The MIL-1553 data bus operates at a current of ~0.9A, which led to the choice of 28-gauge wire to implement it. The RS-422 busses run at very low current (~1mA), thus 28-gauge wire was sufficient for this as well. Note that the MIL-1553 standard is implemented with 2 wires (transmit, receive) while the RS-422 standard is implemented with 6 wires (2 transmit, 2 receive, 2 ground). All of the Control Units are bussed back to the GA CPU called the Main Control Unit (MCU). The MCU also houses the video frame grabber and the two types of data busses. The figure below shows the functions contained within the MCU. Note the redundancy in each hardware component. The frame grabber converts the analog video signal into digital so that it can be sent to ground. This digital video is also sent to the Vision System Controller (implemented in software), which takes the single camera image of the grapple fixture target on the HST and can approximate distance and orientation of the EE. Most of the other functions on the MCU are simply monitoring functions, such as thermal conditions and forces and torques. However, the Joint Controller does play an active role in controlling the GA. It performs the kinematic analysis to determine what joint angles are necessary to move the tip to a given position. When the joint angles are computed, the MCU sends the required joint angle to each of the Joint Control Units (JCU). Each JCU has its own microprocessor on which the control loop is implemented to move that joint to the correct angle. The JCU power and data connections are shown in the figures below. The JCU also houses the thermostat, which sends data back to the microprocessor where the thermal control loop is implemented. The heaters used to control the temperature are called flexible strip heaters and are mounted directly the board. The Motor Drive Amplifier (MDA) is housed on the JCU as well and is used to control the joint motor. The MDA commutates the motor, and implements the Pulse Width Modulation (PWM) to control the motor speed. Resolvers are mounted directly on the joint itself, as are the Resolver to Digital Converters (RDC) so as to avoid signal degradation. Based on the precision requirements derived in the previous section, 16-bit resolvers are necessary to measure joint angle. This is the current state of the art in RDC technology, but there are space rated RDCs available. The resolver used to commutate the motor (located before the gearbox) need only be 8-bit precision for the quadrature motors used at the joints.

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MAIN CONTROL UNIT FUNCTIONAL DECOMPOSITION


56

JOINT CONTROL UNIT POWER INTERCONNECTIONS


57

JOINT CONTROL UNIT DATA INTERCONNECTIONS


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The Camera Control Unit (CCU) is identical to the JCU except that it has additional MDAs to drive the camera pan and tilt motors and of course has power connections for the camera itself. There are two cameras on either side of the boom, one primary and one redundant. Each camera has two motors (pan and tilt) and an LED to light the field of view. Again, the system is made single fault tolerant by duplicating components i.e. the camera. The CCU power and data connections are shown in the figures below. Finally the End Effector Control Unit (EECU) is identical to the CCU except that the cameras located at the EE are not pan and tilt, and there are additional A2D converters on the EE for the force torque sensors. The EE also has a Laser Range Finer (LRF) which is used to determine the distance to HST. The EECU power and data connections are shown in the figures below. Both the pan and tilt and fixed cameras feed their signal back to the MCU as described earlier. A more detailed decomposition of the Vision System is shown below as well.

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CAMERA CONTROL UNIT POWER INTERCONNECTIONS

60

CAMERA CONTROL UNIT DATA INTERCONNECTIONS


61

END EFFECTOR CONTROL UNIT POWER INTERCONNECTIONS


62

END EFFECTOR CONTROL UNIT DATA INTERCONNECTIONS


63

VIDEO CONNECTIONS VISION SYSTEM DECOMPOSTION

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In all of the ECUs redundancy is achieved by duplicating most of the components. The only components that are not duplicated are the gearbox (which is deemed to be very reliable) and the physical motor. The motor windings are duplicated in order to make that system redundant.

CABLING
As described earlier, only three types of cable are used in the GA, gauge 18 wires for power distribution, gauge-28 wires for data distribution and coaxial cable for video distribution. The total cable mass was computed to be 10.56kg, this includes all internal GA cables, cables form the DR to the EM and also cables connecting the GA and the EM. Refer to Appendix C for detailed calculations.

POWER
Power will be generated from the HRV and HST Solar Arrays. The DM solar arrays will generate enough power to support the HST in the event of SA3 power connection is unsuccessful. These solar arrays will recharge the batteries that are mounted in the HRV. The batteries will have a life-cycle of approximately six years for Hubbles survival and it will be of the same type used on the Hubble, Nickel-Hydrogen. The same type is chosen because the recharging system on the HRV can be used on the Hubble as well. It would allow the HRV solar arrays to recharge Hubbles batteries in the event of a malfunction. The batteries will only be used to power the HRV when its solar arrays are no longer in range of the sun. Otherwise, the solar arrays on the HRV will provide power to the EM and DM while at the same time recharging its batteries. This process is similar to the International Space Station where the batteries ensure that the station is never without power, which in our case ensures that the HRV would not be required to seize its servicing operation.

POWER REQUIREMENTS
Electrical Components The average and peak power value of each individual component shown in Table 1 was obtained from data sheets, research papers, and spec sheets. The quantity of each component (Table 2) was derived from the EFBD, our design requirements, and taking into consideration redundancy.

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Component Low Resolution Resolver Resolver-to Digital Converter High Resolution Resolver Flexible Heaters Thermostat/Thermal Switch Microprocessor End Effector Snare Motor Joint Motors Power and Data Plug Motors End Effector Camera LED light Elbow Camera Laser Range Finder Force/Torque Sensor

Quantity 22 22 22 32 16 16 1 6 2 2 2 2 2 2

Peak Power Each (W) 0.168 0.11 0.168 11 2.8 2 30 12 12 1.68 7.5 15 14.2 25

Avg. Power Each (W) 0.1176 0.0913 0.1176 2 0.6 1 25 10 10 1.44 3 10 7.2 5

Reference Type Data Sheet from ADVANCED MICRO CONTROL Data Sheet from AEROFLEX MICROELECTRONIC SOLUTIONS Data Sheet from ADVANCED MICRO CONTROL Spec Sheet from WATLOW SOLUTIONS Data Sheet from HONEYWELL Article from Space Daily Data Sheet from Maxon Motors Data Sheet from Maxon Motors Data Sheet from Maxon Motors Spec Sheet from ALTAAJER Spec Sheet from DEEPSEA POWER AND LIGHT Spec Sheet from PRO SECURITY WAREHOUSE Research Paper by JET PROPULSION LABORATORY Data Sheet from HONEYWELL

Reference # 1 2 1 4 5 14 12 13 12 6 7 8 9 10

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MISSION STAGES
At each different phase of the mission (i.e. Launch, Capture, etc) only certain electrical components will be functioning in order to conserve power. There are seven phases in total and the electrical components being used at each stage is outlined in Table 3 below. In the Launch and Pursuit phase, only the heaters will be required to be operating. They will be monitored and controlled by the thermostat and microprocessor. The heaters will only be turned on when the thermostat detects that the components have dropped to an unsafe operating temperature, then the microprocessor will signal the heaters to turn on. During the Power Up and Diagnostics mode, the GA performs a power up procedure and tests each component individually. For example, there are six joint motors and the testing of each will be done one by one to determine their operating efficiency. This will save power and processing speed since the CPU can evaluate each motor individually rather then attempting to processing all six motors simultaneously. Therefore, only the component with the highest power consumption is taken into account because it will demand the highest average power. Also, the Thermal Control System (heaters and thermostats) will need to be functioning at all times since not all electrical components will be functioning at this phase. This is especially true if the GA is not exposed to sunlight and extra heaters may needed, which is accounted for under the subtitle if sunlight not present in Table 3. In the Deployment Stage, each joint can be activated individually to move the GA out of the EM to conserve power. The other components essential for this operation is outlined in Table 3. Again, the subtitle if sunlight not present then additional heaters may be needed. Otherwise, eight out of the sixteen heaters should suffice, if any is needed at all due to sunlight exposure. During the Capture of the HST, all the components (except those used for redundancy) will be in use. Since the HST is in motion timing would be a critical factor. Components such as joints must move simultaneously rather then individually to perform the quickest and safest capture. However, the heaters will most likely not be required even if the sunlight is not present since all the components are functioning simultaneously and thus, only the thermostat will be required to monitor the temperature. For the Capture of the DR, only a few systems will be required since the DR is stationary and is stowed inside the EM. In other words, the GA software already knows its exact position. Therefore, components such as the Thermal Control System, CPU, torque sensors, position/attitude sensors, laser range finder, and end effector camera and LED light would be required. The joints can also be moved individually since timing is not a critical issue. Furthermore, since only some components are functioning, heaters may be needed to keep the idling components warm. During the Servicing stage, the DR is in control. Components such end effector camera and light, and laser range finder would be obscured and therefore, not needed. However, components such as force/torque sensors, elbow camera, LED Light, microprocessors will still be needed when movement is required by the DR. Some of the heaters may also be needed since there are even 67

fewer components functioning at this stage then the previous stage and thus, it may not matter if sunlight is present or not. Furthermore, since the HRV is now attached to the HST, the motor joints can, again, be activated individually at this stage rather then simultaneously because the position of all the servicing compartments are known and thus, timing is not a critical factor. The last stage is either Down Time or if the DR is stationary. The former would be when the system and its operators are taking a break. The latter would be when the DR is servicing HST at fixed position. At either of these stages, the Thermal Control System would be required to regulate the GAs temperature similar to the Launch and Pursuit stage. The force/torque sensor will be needed only when the DR is performing stationary servicing to detect any excessive torque being applied to the End Effector.
Mission Stage Launch and Pursuit Component Flexible Heaters Thermostat/Thermal Switch Microprocessor Quantity 16 8 8 Avg. Power Each (W) 2 0.6 1 Total 30 1 0.6 2 Total 2 Total 3 10 4.4 0.1176 0.0913 0.1176 1 0.6 2 Total 2 Total 0.1176 0.0913 0.1176 0.6 1 Sum Avg. Power 32 4.8 8 44.8 30 8 4.8 16 58.8 16 74.8 3 10 4.4 0.2352 0.1826 0.2352 8 4.8 16 46.85 16 62.85 1.0584 0.8217 1.06 4.8 8

Power Up and Diagnostics

End Effector Snare Motor Microprocessor Thermostat/Thermal Switch Flexible Heaters

1 8 8 8

if sunlight not present

Flexible Heaters

Deployment of the GA.

LED light Elbow Camera Joint Motor Low Resolution Resolver Resolver-to-Digital Converter High Resolution Resolver Microprocessor Thermostat/Thermal Switch Flexible Heaters

1 1 1 2 2 2 8 8 8

if sunlight not present

Flexible Heaters

Capture of the HST

Low Resolution Resolver Resolver-to Digital Converter High Resolution Resolver Thermostat/Thermal Switch Microprocessor

9 9 9 8 8

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End Effector Snare Motor Joint Motors End Effector Camera LED light Elbow Camera Laser Range Finder Force/Torque Sensor

1 6 1 1 1 1 1

30 10 1.44 3 10 7.2 5 Total 0.1176 0.0913 0.1176 0.6 1 30 10 1.44 3 10 7.2 5 10 2 Total 2 Total

30 60 1.44 3 10 7.2 5 110.18 0.1176 0.0913 0.1176 4.8 8 30 10 1.44 3 10 7.2 5 10 16 105.78 16 121.78

Capture of the DR

Low Resolution Resolver Resolver-to Digital Converter High Resolution Resolver Thermostat/Thermal Switch Microprocessor End Effector Snare Motor Joint Motors End Effector Camera LED light Elbow Camera Laser Range Finder Force/Torque Sensor Power and Data Plug Motors Flexible Heater

1 1 1 8 8 1 1 1 1 1 1 1 1 8

if sunlight not present

Flexible Heater

Servicing

Low Resolution Resolver Resolver-to Digital Converter High Resolution Resolver Flexible Heaters Thermostat/Thermal Switch Microprocessor Joint Motors Elbow Camera Force/Torque Sensor

1 1 1 10 8 8 1 1 1

0.1176 0.0913 0.1176 2 0.6 1 10 10 5 Total

0.1176 0.0913 0.1176 20 4.8 8 10 10 5 58.125

Down Time or DR Stationary

Flexible Heaters Thermostat/Thermal Switch Microprocessor Force/Torque Sensor

16 8 8 1

2 0.6 1 5 Total

32 4.8 8 5 49.8

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Software
REQUIREMENTS
Communication Communication between the GA and DR or GA and ground control will all be done via EMs communication system. In terms of receiving messages and commands, the GA will receive the message from EM and perform it, it does not care whether it was sent from ground or DR; the GA will be a puppet. In terms of the GA sending messages and data to ground or DR, it will tag the messages with a destination following a standard communications protocol. 1. The software shall be able to transfer visual images, other data, in addition to status signals and requests to the EM, as well as receive incoming data, status signals and requests and act upon them appropriately 2. The software shall be able to tag a destination for outgoing messages following the standard protocol Safety One of NASAs requirements was that the GA should not harm the HST. The fact that GA must not touch HST unintentionally implies two things. First, the GA Software will need to plot the path that the GA EE will travel along to get to a certain destination. Second, the GA software will also need to determine the orientation of the entire arm while the GA EE is heading to its destination. The danger of the GA EE hitting the HST is clear, but the possibility of another part of the arm hitting HST is a less obvious danger. In relation to this, the software must be able to recognize and avoid hazards and correct navigation errors in real-time. Avoiding hazards and correcting navigation errors in real-time implies that the processing of sensor input and visual input must be very fast, on the order of 0.1s. This could put a strain on the computing power of the HRV and GA so optimization within the GA Software will be of importance. 3. The software shall be able to receive sensor inputs to calculate its current orientation, position and velocity 4. The software shall be able to map the GA in a map of known obstacles, and use vision and range data such that dangers such as collision can be predicted and avoided Motion The GA must be able to travel along a precisely predetermined path. To do this, it must be able to move by accepting or planning waypoints and determining the angle by which the joints need to move. The GA must also be able to move telerobotically, via live input from ground. Thus, the software must be able to convert rates from ground to joint positions. 5. The software shall be able to plan waypoints, or accept waypoints, for motion 6. The software shall be able to convert rates and position to joint angle information

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GA Performance The GA must have a self-diagnosis. If there is a problem with the functionality of the GA it is important that the problem is discovered before an actual servicing mission. An unnoticed functional problem will cause anomalous behaviour that could cause damage if previously unnoticed. On the other hand, in some cases a functional flaw may be worked around, and the mission may be salvaged. The power levels of the electric circuits and the actuators of the GA must also be monitored to prevent any damage and determine errors. Anomalous power levels can be the first indication that something is wrong with an electrical component. Power level monitoring is an effective method to measure the health of the electrical components of the GA. 7. The software shall be able to perform self-diagnostics and tests on various subsystems 8. The software shall be able to monitor the power draw and look for anomalous signals and behaviour Capture The GA will use the camera data to track its targeted GF (i.e. identify where the GF is in the frame, and show a capture box). The operator on the ground has to try to align the GF within this capture box before moving the EE in for capture. This requirement is demanding on the flexibility of the recognition software. The HST/HST GF may be at any orientation, be under varied lighting conditions, moving at a range of speeds, and in the case of the HST GF may be partially blocked by an obstacle. The GA Software will have to recognize its target in all of these environments. GA must verify that its EE has a locked grip on the HST GF or DR EMGF. Verification of the GA EEs locked grip on the HST GF or the DR EMGF is needed before the GA performs further movements. If the GA EE came loose from either grapple fixture during GA movement the GA, HRV or DR will travel in an unpredictable manner and may cause damage to HST. The verification of the GA EEs locked grip will be simple, likely requiring a single sensor; nevertheless it is very important for preventing damage to HST. 9. The software shall be able to convert analog video data into digital frames, and be able to identify certain targets such as the HST GF and DR EMGF. 10. The software shall be able to detect when the snare motors are taunt and rigidized, as well as when the plugs are ejected and connected to DR.

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SYSTEMS CONTEXT DIAGRAM


Level 0
LED (for camera) Motors & Brakes Motor cmd LED cmd. Pan & Tilt Cameras Microprocessor Camera cmd. Cameras Cam & Motor Camera cmds position Cam images Cameras LED (for camera) LED cmd Position Sensors Sensor data Heater cmd Temp. Thermal Controls

Thermal Controls

Heater cmd Temp Joint Microprocessors Motor cmd

Camera Images

Position Sensors

Sensor data

Motor position Motor cmd Data From EM

GA Main CPU Software 0

Cam, motors, Laser cmd Position, Range, forces

Cam cmd

Range data Laser cmd Heat cmd Temp Sensor data Motor cmd

Laser Range Finder

Motors & Brakes

Data To EM Temp Heater cmd

End Effector Microprocessor

Thermal Control Plug Position Sensors

Force/Torque Sensor

Force data Motor cmd Sensor data Snare Position Sensors

Communications

Thermal Controls

Snare Motor

Plug Motor

Level 1
Camera Range images data

Joint angles

Pos. & Orient.

EE Position Ctrl 2

Joint cmd Force data

Snare position Snare cmd

Process Images 7 Main CPU State Ctrl 1 Comms. Control 6 Thermal Control 5

EE Capture Ctrl 3

Plug position Plug cmd

Comm To EM

Camera Ctrl 4

Cam motor position Cam motor cmd

Comm From EM

Heater cmd Temp

LED cmd

Camera cmds

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Level 1: Subsystem Microprocessors


Joint Motor cmd Joint Motor Ctrl 13 Joint Position data Temp Joint State Ctrl 11 Thermal Ctrl 12 Heater cmd

Comm with Main CPU 22

Joint angle Motor cmds

Cam cmd Cam Motor cmd

LED cmd

Position data Pan & Tilt Camera State Ctrl 8 Thermal Ctrl 9

Temp

Heater cmd

Camera Ctrl 10

Comm with Main CPU 20

Camera position Cam & motor cmds

Positions, range, forces Comm with Main CPU 21 Cam, motor, laser cmds Temp Heater cmd

Force Range data data

Sensor Input 19

Thermal Ctrl 15 EE State Ctrl 14

Snare position Snare Ctrl 16

LED cmd

Camera Ctrl 18

Camera cmd

Plugs Ctrl 17

Plug position Plug Motor cmd

Snare Motor cmd

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Level 2
13 Joint Motor Control
Joint Position data Get Joint angle 13.3 Joint Motor Control 13.1 Joint Motor cmd Send signal to motor 13.4 Interpret Main CPU Position cmd 13.2

Desired joint position Joint State Control

Joint angle

Level 3
Desired angle in Global frame from CPU

Convert absolute/global angle to relative/local 13.1.2

Desired Angle

T2

Desired Angle

Convert angles to Appropriate motor signals 13.1.3

Motor Signal

Joint Motor Control 13.1.1 Joint Position data T6 T2: Trigger convert desired angle to local frame E4: Enable motor drive D4: Disable motor drive T5: Trigger calculate new angle T6: Trigger send new angle to Main CPU

Reaching desired angle E4/D4 New joint data

Motor Driver 13.1.4

Joint Motor cmd

T5

Calculate new absolute angle from resolver data 13.1.5 New Joint Angle New global joint Angle to CPU

Send new absolute joint angle to main CPU 13.1.6

Mini-Specification
Function: Motor Driver 13.1.4 Inputs: Event Flow Input: Enable/disable Data Store Input Desired angle : Data Store Input Motor signal : Outputs: Data Flow Output: Reaching desired angle Pseudocode: If Enabled Send motor signal to motor Read in new joint angle If new joint angle = desired joint angle Send signal to Joint Motor control to indicate it End If

Full software description in Appendix D3 74

DATA DICTIONARY
Name Temperature Heater cmd Joint motor cmd [Appendix D] Brake cmd Joint position data Joint angle data store Camera motor cmd [App D] Camera cmd LED cmd Camera position data [App D] Camera position data store Camera image Comms Force/Torque data [D2] Range data [2] Snare position Snare motor cmd Plug position Plug motor cmd Description Temp data from thermostat to controls On/off signal to heater Output to joint motors from motor ctrl Grouped with motor in diagrams (on/off) Joint resolver data input Joint angle data Output to joint motors from motor ctrl On/off signal to camera On/off signal to LED Cam motor resolver input Camera tilt position data Video feed from camera (analog) RS422 serial data connection (to and from) Force data from force sensors on EE Range data from laser range finder Resolver data from snare motors Output to snare motors Resolver data from plug motors Output to plug motors To 12,9,15,5 HW HW HW 13 2 HW HW HW 10 2 2 EM/2 19 19 16 HW 17 HW From HW 12,9,15,5 13 13 HW 22 10 10,18 10,18 HW 20 10,18 2/EM HW HW HW 16 HW 17 Units N/A N/A % N/A Degrees Degrees % N/A N/A degrees degrees N/A N/A Nm N/A Degrees % Degrees % Range 0,1 0,1 +/- 215 0,1 +/- 180 +/- 180 +/- 28 0,1 0,1 0 to 360 0 to 360 N/A N/A 0 to 200 N/A ~0 to 360 +/- 24 ~0 to 90 +/- 24 Precision 1 1 15 bits 1 15 bits 15 bits 8 bits 1 1 8 bits 8 bits N/A 15 bits 6 bits 12 bits 4 bits 4 bits 4 bits 4 bits Accuracy 1 1 1 1 0.001 1 1 1 1 0.01 1 N/A 1 1 1 1 1 1 1

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Control Systems
This section presents information on the control system for the GA. The mission requirements relating to the design of the control system have been identified through the Functional and Performance Requirements (Refer to Mechanical section), which were also used to derive specifications for the control system itself. These requirements influence the choices for control system specifications such as rise time, damping ratio and bandwidth. They also help to identify various modes of operation, for which the system specifications may differ. These modes include HST capture, HST servicing (i.e. DR attached to GA), and unloaded operations (i.e. GA stands alone without DR). For the HST capture mode the transient and steady state responses are both very important. The rise and settling times must be sufficiently small for the GA to tele-robotic capture HST given the potential rotation scenario of 0.22deg/s described in the Performance Requirements. Also, the requirement that the GA (nor any part of the HRV) shall do no harm to HST requires the overshoot to be sufficiently small. For servicing tasks, during which the DR will be attached to the GA with the end effector (EE), the transient response is not as important as it is during capture, but the steady state and overshoot characteristics are extremely important. Steady state error (governed by the gain of the controller) must be within the accuracy and position repeatability requirements stated in the Performance Requirements. Finally, during unloaded operation (i.e. deployment, stowage, and simple point-to-point maneuvers) where the DR is not attached, the GA is not required to move fast, but must be precise and cautious. In fact, the same requirements that drive the system specifications during servicing drive the specifications in this scenario as well. Thus, modeling the GA as a second order system, the following system specifications have been developed.
Operation Mode Capture 0.5 1.5 3.6 0.28 0.85 0.62

Parameters Rise Time (s) Settling Time (s) Natural Frequency (rad/s) Time Constant (s) Damping Ratio Overshoot (%)

Unloaded 0.75 2.25 2.4 0.42 0.85 0.62

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ACTUATOR & SENSOR SELECTION


This section presents the actuators and sensors needed to perform the various GA tasks and meet the requirements described in Mechanical Section. Required Components Actuators - 6 brushless DC motors (one for each joint), each with a long-life gearbox, brake/clutch assembly, and integrated motor drive electronics - 1 brushless DC motor, gearbox, and drive circuits for the EE snare mechanism - 1 DC motor and drive circuit for the GA/DR EE data and power plug ejection mechanism - Heaters (within the thermal control unit) - Radiators Sensors - 1 Laser range finder on EE - 4 cameras (2 on EE, 2 on elbow) - 12 Thermostats (within the thermal control unit) throughout GA - Force/torque sensor on EE - 16 resolvers (2 for each motor 1 as backup) to measure angular positions of motors Task Function Deployment of GA from EM Capture HST Actuators needed 6 joint motors (actual deployment moves 1 joint at a time to save energy) 6 joint motors, 1 snare motor 6 joint motors 6 joint motors, 1 snare motor, 1 data and power plug motor 6 joint motors 6 joint motors, 1 snare motor, 1 data and power plug motor 6 joint motors Heaters, radiators Sensors needed 12 resolvers associated with all joint motors, 1 elbow camera 1 Elbow camera, 1 EE camera, laser range finder, force/torque sensor, 14 resolvers for motors 1 elbow camera, 12 resolvers 1 elbow camera, 1 EE camera, force/torque sensor, 16 resolvers 12 resolvers 1 elbow camera, 16 resolvers 12 resolvers, 1 elbow camera Thermal sensors, thermostat (within the thermal control unit)

Berth HST to DM Capture DR Servicing with DR Replace DR Stow itself back in EM Thermal controls

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CONTROL ARCHITECTURE
The following diagram presents the control architecture for the GA based on the mission and system requirements and the sensor and actuator descriptions presented in the two previous sections. The arrows show the direction of flow i.e. input/output, while the colored blocks describe the type of input/output.

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Motor Angles, Temps, Tasks Completed, Video, LRF readings Motor Angles, Temps, Tasks Completed, Video, LRF readings Joint Angle Met, Temp Pan/Tilt Angles Met, Video, Temp

Ground Controller

Perform a Certain Task, Or Tele-robotically Move Motor at a Certain Rate

Legend Part of Autonomous Process Part of Either Auto or Tele Process depending on GC

EM

Relay Data from GC

Part of Tele-robotic Process

GA: CPU and Controller Hardware

Move Camera Pan/Tilt to Angles or at Certain Rate Boom Camera: P and Controller Hardware (x2) Camera Tilt Motor and Resolver Pan Motor and Resolver Heater Radiator Thermostat

Plug Pos., LRF readings, Video, Temp

Engage Plug

Joint: P and Controller Hardware (x6)

Joint Motor Angle

Joint Motor and Resolver

Move Joint to Angle or at Certain Rate Joint Motor Voltage Joint Motor Angle Heater Voltage Radiator Voltage Joint Temp

Plug Motor Angle Joint Motor Voltage

End Effector: P and Controller Hardware Plug Motor and Resolver Heater

Joint Temp Heater Voltage Radiator Voltage

Radiator Thermostat

Heater Joint Temp Radiator Thermostat

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SIMULATION WITH MATLAB


Part 1 The component that we have chosen to represent in our controller design is one of the joint motors. An Electro-Mechanical representation of the system can be seen below.

The three components of the system are the electrical system, the motor, and the mechanical system equation. They are labeled 1, 2 & 3, respectively. The equation for the electrical component in the Laplace domain is: LSIa + RIa = ea - KeSm The equation for the motor component in the Laplace domain is: JaS2m + BaSm = KTIa

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The equation for the mechanical component in the Laplace domain is: JLS2L + BLSL = NKTIa Solving for these three equations, including gear ratio relationships, and plugging in all given values of the system produces the following transfer function in terms of the output position versus the input armature voltage:

L/ ea = 0.5/ (0.065S3 + 0.675S2 + 0.7525S)


Parameters

La = 0.05 Henry Ra = 0.5 Ohm N = 10 Ja = 0.1 N-msec2


Ba = 0.05 N-m-sec

armature inductance armature resistance gear ratio armature polar moment of inertia
armature damping coefficient load polar moment of inertia load damping coefficient back e.m.f. constant motor torque constant motor speed current

JL = 3.0 N-msec2
BL = 0.05 N-m-sec Ke = 0.1 volt-sec Kt = 0.5 N-m/amp

m a
Control Signal Output Disturbances ea L Tm

applied motor voltage load output speed torque disturbance acting on load side of motor

*Note: the numerical values were arbitrarily chosen to perform a simulation using MATLAB.

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Part 2 By using the three system equations mentioned in Part 1, the block diagram for the system can be seen below. L ea

Part 3 By modifying the transfer function seen in Part 1 and factoring out an s on the denominator, the transfer function appears as follows:

L/ ea = (1/S)(7.69)/(S2 + 10.385S + 11.577))


Since one pole can be factored out, meaning there is one pole at the zero location on the real axis, this indicates that the system is of Type 1. There also exists an integrator in this transfer function.

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Part 4 Root Locus for a proportional controller is:

Fig. A Root Locus of P Control Closed loop system with proportional controller, at k = 15.6, poles are on the imaginary axis and we are at the verge of instability as shown in Figure A. For the system to be stable, the values of the gain must be 0 < k < 15.62. To make the system completely stable (i.e. for all values of k>0) we must introduce a derivative controller, with zero at z = -2. This will make the system stable for all k>0 as well as eliminate the role of the integrator in the transfer function. The new root locus design is shown in Figure B.

84

Fig. B Root Locus of PD Control Part 5 Bode phase and Magnitude Plots for the proportional controller are shown in Figure C. In order to satisfy the ordinary design parameters of: GM 8dB PM 30 degrees We choose k = 2.59 and as shown in Figure C we get GM = 15.6 dB PM = 38.3 degrees

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Fig. C Bode Plot and Phase Magnitude

86

Part 6 For the specifications of ts < 1.5 sec and > 0.707 we have the restrictions as shown in Figure D. This would give a percentage overshoot of approximately 4.3%.

Fig. D

87

Part 7 Bandwidth of proportional controller system is c = 0.114 as shown in Figure E.

Fig. E Bandwidth of P Control

88

Bandwidth of the PD Control is c = 0.141 shown in Figure F.

Fig. F Bandwidth of PD Control

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GA And DR Interfacing
MECHANICAL INTERFACE
End Effector and DR Grapple Fixture We have chosen the End Effector type to be similar to that of the Canadarm 2 EE with modifications. For Power and Data interfacing, we will have only two external port connections, as opposed to four in the Canadarm 2 EE. The connections will be made from male prongs on the End Effector (Fig. 1) and inserted into female connections on the DR Grapple Fixture. These prongs are extended by motors from inside the attachment to prevent damage during capture of HST and DR. The DR GF will have three lobes (Fig.3), and the GA EE will have three matching recesses in the inner EE wall. This will allow the DR GF/ GA EE interface to properly align our power/data interface. In addition, the three lobes react to torque/shear forces and improve the structural rigidity of our GA/DR interface. Both the DR and HST GFs have the same physical dimensions so the GA EE can interface with both GFs in the same manner. To interface the GA EE will surround a GF, the snare motors will then engage and draw the snare wires around the GF pin. The snare wires will tighten, and the three lobes will align the GA EE as the GA EE is pulled firmly against the GF. Dimensions of our EE: Outer Diameter: Inner Diameter: Length: Dimensions of the GF: 40 cm 36 cm 40 cm

Grapple Fixture / Target


Outer Baseplate Diameter: Inner Baseplate Diameter: Length of Grapple Shaft: 57 cm 37 cm 27 cm

90

Capture Envelope We will assume that the capture envelope is the area where, if the GA EE snares are activated then the GA EE and DR GF will mate. Hence, the capture envelope corresponds to a cylindrical area around the DR GF. The capture envelope is a cylinder rougly corresponding to the size of the GA EE. For capture the GF shaft must be within the inner diameter of the GA EE, due to the thickness of the GF shaft this corresponds to a capture envelope diameter about the pin of 34 cm. The snare wires are located 5 cm within the edge of the GA EE, and can engage the GF shaft inwards 27 cm. This corresponds to a capture envelope depth of 22 cm. Capture Envelope Dimensions: Capture Envelope Diameter: 34 cm Capture Envelope Height: 22 cm Loads The End Effector must be able to sustain the larger of the torques generated by the HST during capture or by the DR meeting its stopping criteria. When the GA captures the HST it undergoes a torque of approximately 94.7Nm calculated from team X-Sites Propulsion assignment. To meet the DRs stopping criteria, the arm only experiences a torque of 56.3 Nm (see Appendix: DR Stopping Calculations). Thermal Interfacing In order for the End Effector and the DR Grapple Fixture to mate properly, the dimensions for both components must be same. For example, the lobes and respective lobe inserts must be within tolerance to achieve a proper fit. However, these tolerances can be compromised due to thermal expansion or contraction of the materials. To have consistent thermal interfacing between the components, the coefficient of thermal expansion should be similar. This will enable uniform expansion or contraction due to thermal effects. Our solution is to use the same material must be used on both the GA End Effector and the DR Grapple Fixture. However, ideal mating assumes that both components are subject to the same thermal conditions. If the GA EE and the DR GF are not at the same temperature then a partial mating shall occur to allow for physical contact between the GA EE and the DR GF. Over a short period of time the EE/GF will reach thermal equilibrium. Then the GA EE / DR GF can complete properly.

91

Fig. GA End Effector (not to scale)

Fig. DR Grapple Fixture (not to scale)

92

Fig- HST Grapple Fixture

ELECTRICAL INTERFACE
Power The DR will run on 28VDC, and consume 1000 W on average, with a peak power consumption of approximately 1500 W. This means that the GA must supply power from the EM with wires of gauge #2. For redundancy, two pairs of wires shall run the length of the GA for power delivery. The power connection will feature a delivery prong, a return prong, and a ground prong (Refer to Figure 3). Inside the body of the DR, one EMI filter will be attached to each power cable to prevent unwanted noise passing into the DR circuitry from the GA, and vice versa. Data The GA and the DR will each have separate data communications to the EM via RS 422 Serial Data interfaces. The communciations for the DR to EM interface will run through a RS 422 Serial Data bus via the GA. The GA and DR will each communicate only to the EM, and will receive commands only from the EM.

93

SOFTWARE INTERFACE
NOTE: All messages relayed to/from GA, DR & ground control are done via EMs communications. The message packets will be formatted in a standard protocol, and tagged with a destination, which is read by EM to determine the appropriate delivery location.

CAPTURE PHASE Assume that the GA and DR have mated. The power and data plugs are in. Power has flown into DR which powers up their processor. After an initial boot up they confirm to EM that they received power.
1.1 DR sends signal to EM, which sends it to GA and ground control to confirm that power was received 1.2 GA acknowledges to DR via EM that message about power was received

From Dexterous Robot (DR) From Grapple Arm (GA) From Ground Control (GC)

DR has turned on its systems to run its own start up procedure. After they have checked everything on themselves, they check the data connection between them and GA.
1.3 DR tells GA that it is up and running, and that it is ready to test data transfer with GA 1.4 GA acknowledges the message and sends a predetermined set of data (known to both robots) 1.5 DR checks data against the known set to make sure that all data was received as expected 1.6 DR sends GA signal that communication was successful 1.7 DR sends signal to say that it will send test data to GA

If not 1.5.2 If data transfer not successful, DR sends message to GA to try again

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1.8 DR echoes the predetermined data it received back to GA

1.9 GA then checks to see if the data it receive is as expected

1.10 GA sends signal to DR saying it received all the data ok

1.19 DR and GA both relay its communications testing log to ground control

If not 1.9.2 If data transfer unsuccessful, GA sends DR message to try again

After DR has completed all its other checking, it sends a signal that it is ready for extraction from EM cargo bay.
1.20 DR sends signal to GA and ground control that it is ready to be extracted 1.21 GA requests permission from ground control to initiate extract sequence 1.22 Ground control sends signal to GA and DR initiate extract sequence (DR ensures its in extract position) 1.23 DR sends signal to GA to indicate that it is ready for extraction 1.24 GA acknowledges DRs message and proceeds to extract DR from bay then awaits command from DR

If not 1.21.2 If ground control does not give permission, await further instructions

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SERVICING PHASE
2.1 DR determines next command from mission database 2.2* DR sends command information to GC then awaits response from GC 2.3 GC reviews command information and visual data 2.4* GC sends one of three responses to DR 1.) proceed 2.) skip command 3.) new command * Information sent between DR and GC is via GA and EM. Information about the intended recipient will be sent along with the original data. The subsystem will then relay the information or process it according to the intended recipient.

Proceed
2.5 DR proceeds with command. There are two types of commands, those for DR and those for GA. GA 2.6 DR sends command to GA and awaits verification 2.6 GA receives command and sends the same information back for verification purposes 2.7 DR receives the command back and verifies its the same one it sent, if yes, send OK signal, if no, resend command 2.6 If OK signal received, implement command (details not shown). Otherwise, repeat verification process. 2.7 GA sends OK signal to DR and awaits further commands from DR 2.8 DR receives OK from GA and repeats process starting from next command in the mission database 2.6 DR implements command (detailed DR FBD for this process not shown) 2.7 DR repeats process starting with next command in the mission database

Skip Command
2.5 DR repeats process starting from next command in the mission database

New Command
2.5* DR awaits new command from GC 2.6 GC calculates new command and ensures they will not harm HST 2.7* GC sends new command to DR. 2.8 DR receives new command. Continue as described under PROCEED

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STOWING PHASE
3.1 GA checks mission database to ensure mission complete 3.2 GA requests permission from GC to stow DR 3.3 GC checks DR bay door sensors indicate bay door is open and DR stowing latches are open 3.4 GC grants permission for GA to stow DR 3.5 GA requests DR to enter stow configuration

3.6 DR requests command confirmation

3.7 GA confirms request for DR to enter stow configuration

3.8

3.9 DR signals GA it has entered stow configuration

3.10 GA moves DR directly over DR cargo bay

3.11 GA requests GC to visually confirm that DR cargo bay door is open

3.12 GC confirms DR cargo bay door open

3.13 GA uses closed-loop algorithm using camera system and visual aids to stow of DR in cargo bay

3.14 GA requests GC to engage DR stowing latches

3.15 GC requests command confirmation

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3.16 GA confirms request for GC to engage DR stowing latches

3.17 GC commands DR stowing latches to engage

3.18 GC signals GA that DR stowing latches are engaged

3.19 GA initiates test program to confirm DR is fully secure. (GA moves slightly and confirms force sensor readings)

3.20 GA commands its end effector cameras to turn on. 1 camera is left on for vision

3.21 GA requests DR to shut down

3.22 DR requests command confirmation

3.23 GA confirms request for DR to shut down

3.24 DR commands computer to undergo shut down process and power off

3.25 GA confirms DR shutdown based on lack of data transmission from DR

3.26 GA retracts DR/GA power/data plugs

3.27 GA commands EE snares to release DR grapple fixture

3.28 GA pulls away from DR in 2m linear retraction

3.29 GA requests GC to close DR cargo bay door

3.30 GC requests command confirmation

3.31 GA confirms request for GC to close DR cargo bay door

3.32 GC closes DR cargo bay door

3.33 GC signals DA that DR cargo bay door is closed

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30% Power Reduction Proposal


This proposal is in response to the 30% power reduction request posed by Ross Gillet. Our Solution: 1) Remove all radiators from the Team X-Site GA. 2) Maintain temperature at minimum levels allowed by our electronics (~358C) These two proposals will reduce the heat output needed for the heaters. If the GA electronics overheat our brakes will automatically be applied and our system will shut down to cool off.

Compliance Table
The following table summarizes NASAs mission requirements and how our system meets them. Mission Requirements Provide the capability to safely and reliably de-orbit HST at the end of its useful scientific life Provide the capability to robotically extend the scientific life of HST for a minimum of 5 (TBR) years Provide robotic installation of the WFC3 and COS instruments Provide single-fault tolerance Ensure that Level I performance is not degraded by robotic servicing Compliance The GA is used to capture HST, and berth HST with the DM, which gives the HST means to deorbit safely at the end of its useful life. The GA does so through tele-robotic means. The GA is also designed with such precision, speed, and sensory units such that it can meet HSTs tumble and track its GF to ensure a successful capture. The GA in conjunction with the DR services the HST. For this requirement in particular, the GA aids in replacing the failing gyros with new ones in the WFC3. The GA can either use a preplanned set of waypoints to move the DR into its workspace, or it can take and execute an inputted set of waypoints. The GA in conjunction with the DR replaces the old WF/PC2 with the new WFC3. They also augment HSTs batteries, and install new COS instruments. The GA meets this requirement by implementing redundant components, and also having back-up methods for performing operational tasks. The possible hazards have been outlined in detail throughout the mission (Appendix A). Hazard controls, and avoidance tactics have been implanted to ensure that the GA does not unintentionally damage the HST.

Conclusions
Without our eyes, we would be blind to our world. Without the Hubble Space Telescope, we would be blind to our universe. Considering the cost to design and launch a new telescope, it would make sense to repair and extend the life of Hubble, a staple of human ingenuity. Our grapple arm design meets every requirement from NASA to save, and augment the Hubble, and should in fact exceed all expectations. 99

Just to summarize our system briefly, mechanically, we are modeled similar to the original CanadArm, with 2 booms and 6 joints providing 6 degrees of freedom. In the shoulder, there are two joints (roll and pitch), in the elbow one joint (pitch), and in the wrist three (pitch, roll, yaw). The joint motors were selected based on precision, torque and speed requirements both given and arising from operations. Various capture and worst case scenarios were analyzed to determine that our max load and torque would occur during the capture of HST, with a maximum EE torque for snaring at 158.4 Nm, and maximum joint torques at 94.7 Nm. The HSTs predicted max spin rate of 0.22 deg in every orientation during capture dictated our joint speeds and amount of time allowable for capture. Given also was the required position repeatability of 0.16 inches, which translated to a joint precision of 0.0187 degrees, which gave us a precision of 15 bits, dictating a software necessity. At the end of the arm lies an end effector. The end effector is equipped with snare wires to grip and rigidize on the coupling GF. The snare motor was selected to be able to accommodate 1.8 rpm and 158.4 Nm torque. The EE is also equipped with 2 cameras, which send a video feedback to be captured and digitized by the main CPU and, along with laser range finder data, is relayed to ground control for telerobotic manipulation. An additional set of pan and tilt cameras lie on the boom near the elbow. These are used by the tele-operator to guide the GAs movement and monitor the environment for hazards. One more important piece of hardware in the EE is the plugs, which provide a means of data and power to be transferred to the dexterous robot. Electrically, we have a redundant set of nearly all components, and data and power lines. From the EM, we receive 4 power lines, with 2 sets of different power sources from the EM. We also have 4 data lines, 2 sets for redundancy. All communication to ground or DR is done through EM via the data lines. Electrically, we have a distributed architecture, with 2 microprocessors (redundancy) for each major subsection: Joint (x6), pan & tilt boom cameras (x2), and EE (x1). In each joint, we have 2 sets of thermal controls, brakes, resolvers, and motor windings for redundancy. For the boom cameras, we have 2 cameras, a motor and mount each, 2 resolvers each, and thermal controls. For the EE, we have the snare motor (with 2 windings) and 2 plug motors, a laser range finder, 2 cameras, and a force/torque sensor. Each component and its redundant counterpart are connected to a different power and data line (main and redundant). This redundancy provides our system with single fault tolerance in case of malfunction. The software reflects this distributed architecture with small pieces of code for the microprocessors to gather sensor signals and interpret before sending it to the main CPU. In terms of operation, the capturing of the HST and DR will be done telerobotically, and the positing of the DR for servicing will be done autonomously (although this can be over-ridden to be done manually.) A frame grabber in the main CPU will digitize the camera images before sending it to ground. Due to the time delay in communications, the ground control will have predictive software for estimating current positions of the moving HST while capture, all of which is detailed in our interfacing section.

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In short, our system achieves all the requirements, and attempts to use the most efficient method available. X-Sites believes in the quality of our design and our clients can rest assure we will deliver.

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Appendix A
A1: FULL FUNCTIONAL FLOW BLOCK DIAGRAM (FOR HRV + GA + DR)
1 Launch & Pursuit 2 Proximity Operations 3 Capture 4 Servicing 5 EM Jettison & Disposal

1. Launch & Pursuit


1.1 GA in tie-down position on EM surface 1.2 DR in stowaway position inside isolated cargo bay

2 Proximity Operations
2.1 As HRV prep for capture, power up GA and run system check

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3 Capture
3.1 Release pins tying GA down 3.2 GA deploys/unfolds 3.3 GA runs full system check and functional simulations 3.4 GA assumes ready to capture pose 3.5 HRV positions HST GF in Capture Box, allowing GA to acquire the GF target

3.6 Ground Control monitors HST through video, determines HST roll rates and GF capture windows

3.7 In a GF capture window Gnd Ctrl adjusts GA position /orientation enabling ready to capture conditions

3.8 Ground Control tele-robotically controls GA EE to surround HST GF

3.9 EE captures HST GF and brings HST to near rest relative to HRV

3.10 GA movement enabled to join HRV and HST modules together

3.11 GA releases HST GF and folds up to dormant position

3.8 Ground Control tele-robotically controls GA EE to surround HST GF


3.8.1 GC adjusts GA so EE cameras target GF 3.8.2 Predictive displays project the current positions of the GA EE and HST GF 3.8.3 GC telerobotically uses pan and tilt boom camera to watch for hazards 3.8.4 GA, telerobotically controlled, keeps GF in view while reaching towards it with GA EE 3.8.5 GA EE surrounds HST GF

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3.9 EE captures HST GF and brings HST to near rest relative to HRV
3.9.1 EE locks with HST GF 3.9.2 HST and HRV relative velocities are brought to rest

Servicing

General operations of GA and DR that are performed repeatedly for each service task is outlined in detail below (4a and 4b) and referenced therafter 4a GA takes out DR to perform servicing operations
4a.1 GA deploys/unfolds 4a.2 DR cargo bay door opens via ground control 4a.3 GA uses EE camera to locate the EMGF on DR. 4a.4 Predictive displays project the current positions of GA EE and DR EMGF 4a.5 GA, telerobotically controlled, keeps DR EMGF in view while reaching towards it with GA EE

4a.6 GA EE captures DR EMGF

4a.7 GA connection allows DR to power up

4a.8 EM releases pins/bolts/straps on launch locks holding DR down

4a.9 GA maneuvers DR out of cargo bay by linear retraction, and video verification

4a.10 DR unfolds in space and does a full system check

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4b DR selects desired tool


4b.1 Ground station selects the desired tool 4b.2 DR positions cameras in the vicinity of the desired tool 4b.3 Image data transferred to ground 4b.4 DR moves automatically to position itself over the desired tool 4b.5 Operator confirms position of DR and chooses one of 3 options (4b.5.a, b, c)

4b.6 DRs EE locks with tool and withdraws it from its compartment

4b.5 Operator confirms position of DR and chooses one of 3 options (4b.5.i, ii, iii)

4b.5.i triggers next move in auto mode

4b.6 opts for another image capture

4b.6 manually adjusts the tip position

Servicing tasks to be performed


4.1 Conduit Deploy/ Battery Augmentation 4.2 Change-out for WFC3 4.3 Change-out for RSU 4.4 Stow DR

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4.1 Conduit Deploy/ Battery Augmentation


4.1.1 GA deploys/unfolds 4.1.2 GA takes out DR to perform servicing operations (4a) 4.1.3 GA maneuvers DR to the tools, and gets the diode box assemblies II (DBA II) handle clamp tool for attaching conduit to diode boxes in 1 hand (4b) 4.1.4 Deploy conduit from DM 4.1.5 Make connector interface plate attachment

4.1.6 Attach harnesses to HST handrails

4.1.7 Connect batteries to HST Diode Box Assemblies II (DBA II)

4.1.4 Deploy conduit from DM


4.1.4.1 Cargo bay door containing conduit is opened via teleoperator 4.1.4.2 Conduit is partially ejected a set amount from its holding bay

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4.1.5 Make connector interface plate attachment


4.1.5.1 GA maneuvers DR close to conduit end connecter interface plates 4.1.5.2 Ground operator uses cameras to determine how DR should capture the plate 4.1.5.3 DR grabs one DBA II connector interface plate (-V2 or +V2) from conduit in free hand 4.1.5.4 GA maneuvers DR with DBA connector in hand up to HST DBA II handle 4.1.5.5 Install connector interface plate on DBA II handle with DRs DBA II handle clamp on EE

4.1.5.6 DR puts tool back in its box

4.1.6

Attach harnesses to HST handrails


4.1.6.1 DR gets harness attachment tool for attaching harness to HST handrails (4b) 4.1.6.2 GA maneuvers DR to harness 4.1.6.3 DR uses hand to grab harness, starting from the edge of the conduit 4.1.6.4 Ground operator uses cameras to position harness against HST handles 4.1.6.5 DR attaches the harness with its tool

4.1.6.6 DR moves along the line to the next position

4.1.6.7 Again, DR attaches harness to indicated handrails using harness attachment tool

4.1.6.8 Repeat attaching harness to handrails (4 places for V2 and 8 places for + V2)

4.1.6.9 DR puts tool back in its box

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4.1.7 Connect batteries to HST Diode Box Assemblies II (DBA II)


4.1.7.1 GA maneuvers DR to tool box, and gets DBA II connector tool (4b) 4.1.7.2 GA maneuvers DR to HST diode box 4.1.7.3 DR removes P8A connector from old DBA II using connector tool 4.1.7.4 DR then attaches P8A connector onto J8B connector on newly installed interface plate 4.1.7.5 DR removes P6A connector from old DBA II using connector tool

4.1.7.6 DR then attaches P6A connector onto J6B connector on newly installed interface plate

4.1.7.7 Repeat installation steps above for other diode box

4.1.7.8 DR replaces the tool

4.2 Change-out for WFC3


4.2.1 GA deployed and DR removed (4a) 4.2.2 Install new ground strap temp stow fixture 4.2.3 Install WF/PC II Interface Plate 4.2.4 Release blind mate connecter on WF/PC II 4.2.5 Release ground strap and install on temp stowage fixture

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4.2.6 Release A-Latch

4.2.7 Remove and stow WF/PC II

4.2.8 Retrieve WFC3 and begin translation to HST

4.2.9 DR+GA move WFC3 into empty telescope space on HST

4.2.10 Once WFC3 is in place, DR drives A-latch

4.2.11 Re-install ground strap onto WFC3

4.2.12 DR engages blindmate mechanism

4.2.13 Detector vent valves (2) opened by solenoid values

4.2.14 Final stow of WF/PC II

4.2.2 Install new ground strap temp stow fixture


4.2.2.1 Cargo bay with temp stow fixture opens 4.2.2.2 GA guides DR to bay 4.2.2.3 DR grabs temp stow fixture 4.2.2.4 DR releases stow fixture from bay attachments (7/16 hex interface) 4.2.2.5 DR removes temp stop fixture from cargo bay (linear retraction)

4.2.2.6 GA brings DR and temp stow fixture to handrail above WFC

4.2.2.7 DR places temp stow fixture on handrail

4.2.2.8 DR attaches temp stow fixture to handrail

4.2.2.9 GA backs away from workspace

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4.2.3 Install WF/PC II Interface Plate


4.2.3.1 GA moves DR back to cargo bay 4.2.3.2 DR removes 3 guide studs securing WF/PC II interface plate in cargo bay 4.2.3.3 DR grabs WF/PC II interface plate with 1 arm 4.2.3.4 DR removes last guide stud securing WF/PC II interface plate 4.2.3.5 DR removes WF/PC II plate from bay

4.2.3.6 GA moves DR + plate to WF/PC II location

4.2.3.7 DR places WF/PC II plate in position with guide studs (using 1 arm)

4.2.3.8 DR attaches WF/PC II plate with 1 guide stud

4.2.3.9 DR releases WF/PC II plate from grip

4.2.3.10 DR secures WF/PC II plate in position with other 3 guide studs

4.2.3.11 GA backs DR away from workspace

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4.2.4 Release blind mate connecter on WF/PC II


4.2.4.1 GA moves DR to blind mate connector 4.2.4.2 DR releases blind mate connector 4.2.4.3 GA backs DR away from workspace

4.2.5

Release ground strap and install on temp stowage fixture


4.2.5.1 GA moves DR to WF/PC II ground strap 4.2.5.2 DR grabs ground strap 4.2.5.3 DR releases ground strap from WF/PC II 4.2.5.4 DR pulls ground strap away from WF/PC II 4.2.5.5 GA + DR move ground strap to temp stow fixture

4.2.5.6 DR places ground strap in proper location on temp stow fixture with 1 arm

4.2.5.7 DR secures ground strap to temp stow fixture with other arm

4.2.5.8 GA + DR back away from workspace

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4.2.6 Release A-Latch


4.2.6.1 GA moves DR to A-latch position on WF/PC II 4.2.6.2 DR grabs WF/PC II via WF/PC II interface plate with 1 arm 4.2.6.3 DR releases Alatch with other arm

4.2.7 Remove and stow WF/PC II


4.2.7.1 DR + GA linearly retract the WF/PC II from telescope 7.5 ft 4.2.7.2 DR + GA move WF/PC II to the temp stow fixture 4.2.7.3 DR place WF/PC II on the temp stow fixture with 1 arm 4.2.7.4 DR attaches WF/PC II on the temp stow fixture with A-latch with other arm 4.2.7.5 Back away from workspace

4.2.8

Retrieve WFC3 and begin translation to HST


4.2.8.1 Move DR+ GA to cargo bay 4.2.8.2 Thermal contamination cover is retracted from WFC3 4.2.8.3 DR is moved to WFC3 ground strap 4.2.8.4 DR grabs ground strap with 1 arm and releases ground strap with the other 4.2.8.5 DR moves ground strap to cargo bay storage fixture with 1 arm and attaches it with the other

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4.2.8.6 DR grabs WFC3

4.2.8.7 DR releases A-latch with

4.2.8.8 DR + GR linearly retract WFC3 7.5 ft from cargo bay of HRV

4.2.8.9 DR_GA move WFC3 to WFC empty space

4.2.11 Re-install ground strap onto WFC3


4.2.11.1 DR grabs ground strap from temp stow fixture 4.2.11.2 DR places ground strap on WFC3 and secures it

4.2.12 Final Stow of WF/PC II


4.2.14.1 DR+GA move to WF/PC II and grabs WF/PC II interface plate 4.2.14.2 DR releases WF/PC II A-latch 4.2.14.3 DR + GA linearly retract WF/PC II 4.2.14.4 DR+ GA move WF/PC II to cargo bay WFC3 empty storage space 4.2.14.5 DR secures WF/PC II via A-latch

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4.3

Change-out for RSU


4.3.1 Move GA to conduit/ECU end 4.3.2 DR grabs conduit/ECU end 4.3.3 DR moves it to circular connector interface on WFC3 4.3.4 DR attaches conduit/ECU end to circular connector interface on WFC3 4.3.5 DR opens bay 1 door

4.3.6 DR removes terminator plug on 486 (59)

4.3.7 DR places terminator plug in HRV cargo bay

4.3.8 DR grabs RSU 1553 bus end

4.3.9 DR moves it to bay 1 of HST

4.3.10 DR connects RSU 1553 bus end to 59

4.3.11 DR closes Bay 1

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4.4

Stow DR
4.4.1 DR folds into stow configuration 4.4.2 GA moves directly over DR cargo bay 4.4.3 GA Autonomously lowers DR into the DR cargo bay to within 0.16 accuracy. 4.4.4 Stowing latches fix DR in stow position 4.4.5 DR shuts down.

4.4.6 GA EE detaches power/data plugs from DR EMGF

4.4.7 GA EE releases DR EMGF and retracts 2m linearly

EM Jettison & Disposal


5.1 DR back in stow-away position inside isolated cargo bay 5.2 GA folds back to original tie-down position on EM surface, reattaching the physical binds 5.3 Ground control sends signal for EM to detach from DM 5.4 EM performs evasive maneuvers to navigate away from HST 5.5 EM performs deorbit burns to reenter and burn up in atmosphere along with GA and DR

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A2: FUNCTIONAL FLOW AND HAZARD CONTROLS


The functional flow process is outlined below in list form. The hazards for each section of the mission are in boxes following that sections functional flow.
1 Launch & Pursuit 1.1 GA in tie-down position inside isolated cargo bay on EM 1.2 DR in stow-away position inside isolated cargo bay

Hazards: 1.1 a) GA gets damaged in transit Causes: - GA is jostled in storage bay Control: - secure fasteners to hold GA in place and foam-padded walls in storage bay 1.2 a) DR gets damaged in transit (same as 1.1(a)) 2 Proximity Operations 2.1 As HRV prep for capture, power up GA and run system check Hazards: 2.1 a) GA does not power up (electrical) Causes: - loss of power, possibly electrical short circuit, or battery problems Control: - back-up system, back up power source b) GA finds system error (software) Causes: - software issues Control: - debug software thoroughly prior to mission, and bug reports to ground control so they can isolate the problem, re-program, and upload new software 3 Capture 3.1 Ground control commands release of pins/bolts/straps tying GA down (elbow, wrist, shoulder and end effector tie downs) 3.2 GA deploys/unfolds 3.3 GA runs full system check and functional simulations 3.4 GA assumes ready to capture pose 3.4.1 open/activate GA end effector for capture 3.5 HRV positions HST GF in Capture Box, allowing GA to acquire the GF target 3.6 GA rotates and positions itself until position/orientation meets that of HST, enabling ready to capture conditions 3.7 HRV triggers GA to Capture and turns off thrusters 3.8 GA tracks GF target with EE camera and closed loop vision processing/servicing 3.8.1 EE cameras on GA keep target GF in target area 3.8.2 GA manoeuvred to keep GF in view while reaching out towards it with its EE 3.8.3 EE couples with the HST GF 3.9 EE captures HST GF and brings HST to near rest relative to HRV 3.9.1 EE locks with HST GF 3.10 Join HRV and HST modules together with GA 3.11 GA releases HST GF and folds up to dormant position Hazards: 3.1 a) Erroneous command from ground Causes: - operator error Control: - autonomous monitoring of GA movements via camera and on-board processor to detect if it comes within range of collision with another object, and prevents it from occurring; redo command. b) Loss of communication with ground cannot release GA Causes: - signal failure; electrical problem

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3.2 3.3 3.4 3.5

3.6 3.8 3.9

3.10

- try to communicate via a different satellite; try to communicate through another module, or back-up comms c) Not all straps released Causes: - mechanical failure; communication failure Control: - make sure simulation tests work before mission, or try manoeuvring GA out underneath non-working strap; same as 3.1(b) a) Loss of function of GA - wont deploy after release Causes: - mechanical damage during transit Control: - same as 1.1(a) a) Finds system error/performance error - same as 2.1(b) a) Loss of function EE non-functional/ functioning improperly Causes: - mechanical, electrical, software Control: - 1.1(a), have redundant/back-up systems, 2.1(b) a) GA hits HST while positioning Causes: - incorrect positioning; EE distance sensors/ cameras malfunctioning Control: - autonomous monitoring of GA movements via camera and on-board processor to detect if it comes within range of collision with another object, and prevents it from occurring; use other cameras to guide arm (i.e. pan-and-tilt on arm) b) camera on EE doesnt work Causes: - electrical, mechanical, data not relayed back (communication) Control: - 1.1(a), 3.1(b), if problem still not fixed, use other cameras a) same as 3.5(a) a) same as 3.5(a) and 3.5(b) a) same as 3.5(a) b) EE misses HST GF Causes: - malfunction in control-loop processing Control: - try again, 3.5(a) ensures no collision, if software problem: 2.1(b) c) GA cannot handle the torque from HST, and thus cannot bring it to rest and rotates with it or breaks off Causes: - poor mechanical design Control: - do calculations and testing before hand a) HRV and HST collide Causes: - incorrect positioning Control: - autonomous monitoring of HRV movements via camera and on-board processor to detect if it comes within range of collision with another object, and prevents it from occurring; move together very, very slowly such that if a light collision occurs, no damage is incurred to either

Control:

4 Servicing Common Functions Required from GA and DR When Servicing 4a GA takes out DR to perform servicing operations 4a.1 GA deploys/unfolds 4a.2 DR cargo bay door open via ground control 4a.3 GA uses cameras to locate the electro-mechanical grapple fixture (EMGF) on DR 4a.4 GA closes in on EMGF, until it falls within the target capture box 4a.5 GA tracks target with EE camera and closed loop vision processiong/servoing 4a.6 GAs EE captures DRs EMGF 4a.7 GA connection allows DR to power up 4a.8 Release pins/bolts/straps on launch locks holding DR down 4a.9 GA manoeuvres DR out of cargo bay 4a.9.1 GA uses inlaid dead-reckoning system to pull DR straight out 4a.9.2 GA verifies that with pan-and-tilt camera system 4a.10 DR unfolds in space and does a full system check

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Hazards: 4a.1 a) Loss of function of GA - wont deploy after release (same as 3.2(a)) 4a.2 a) Loss of communication (same as 3.1(b)) 4a.6 a) GA collides with DR without capturing (same as 3.5(a)) 4a.7 a) DR doesnt power up (same as 2.1(a)) 4a.9 a) GA + DRs retraction not completely linear and end up hitting EM sides Causes: - mechanical jerk in joints causing deviation; operator error Controls: - do simulations to check for issues before performing actual task; use cameras on GA and DR to move out slowly 4a.10 a) DR finds system error (same as 2.1(b)) 4b GA maneuvers DR to the tools, and the tool for attaching conduit to diode boxes attached to DR 4b.1 Ground station selects the desired tool 4b.2 DR positions cameras in the vicinity of the desired tool 4b.3 Image data transferred to ground 4b.4 DR moves automatically to position itself over the desired tool 4b.5 Operator confirms position of DR and : 4b.5.1 triggers next move in auto mode 4b.5.2 opts for another image capture 4b.5.3 manually adjusts the tip position 4b.6 DRs EE locks with tool and withdraws it from its compartment Hazards: 4b.1 a) Loss of communication (same as 3.1(b)) 4b.4 a) DR collides into HST Causes: - incorrect positioning; cameras malfunctioning Control: - autonomous monitoring of GA+DR movements via camera and on-board processor to detect if it comes within range of collision with another object, and prevents it from occurring; use other cameras to guide arm (i.e. pan-and-tilt on arm) 4b.5 a) Loss of communication (same as 3.1(b)) 4b.6 a) DR cannot lock with tool Causes: - manufactured incorrectly; something damaged in transit Controls: - make sure specifications met and tested on Earth; 1.2(a) Servicing Tasks 4.1 Conduit Deploy/ Battery Augmentation 4.1.1 GA deploys/unfolds 4.1.2 GA takes out DR to perform servicing operations (4.1) 4.1.3 GA manoeuvres DR to the tools, and gets the diode box assemblies II (DBA II) handle clamp tool for attaching conduit to diode boxes in 1 hand (4.2) 4.1.4 Deploy conduit from DM 4.1.4.1 Cargo bay door containing conduit is opened 4.1.4.2 Conduit is partially ejected a set amount from its holding bay 4.1.5 Make connector interface plate attachment 4.1.5.1 GA manoeuvres DR close to conduit end connecter interface plates 4.1.5.2 Ground operator uses cameras to determine how DR should capture the plate 4.1.5.3 DR grabs one DBA II connector interface plate (-V2 or +V2) from conduit in free hand 4.1.5.4 GA manoeuvres DR with DBA connector in hand up to HST DBA II handle 4.1.5.5 Install connector interface plate on DBA II handle with DRs DBA II handle clamp on EE 4.1.5.6 GA moves DR to tool box 4.1.5.7 DR puts tool back in its box 4.1.6 Attach harnesses to HST handrails 4.1.6.1 GA manoeuvres DR to tools, and gets harness attachment tool for attaching harness to HST handrails (4.2) 4.1.6.2 GA manoeuvres DR to harness 4.1.6.3 DR uses free hand to grab harness, starting from the edge of the conduit

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4.1.6.4 Ground operator uses cameras to position harness against HST handles 4.1.6.5 DR attaches the harness with its tool 4.1.6.6 DRs free hand moves along the line to the next position 4.1.6.7 Again, DR attaches harness to indicated handrails using harness attachment tool 4.1.6.8 Repeat attaching harness to handrails (4 places for V2 and 8 places for + V2) 4.1.6.9 GA moves DR to tool box 4.1.6.10 DR puts tool back in its box 4.1.7 Connect batteries to HST Diode Box Assemblies II (DBA II) 4.1.7.1 GA manoeuvres DR to tool box, and gets DBA II connector tool (4.2) 4.1.7.2 GA manoeuvres DR to HST diode box 4.1.7.3 DR removes P8A connector from old DBA II using connector tool 4.1.7.4 DR then attaches P8A connector onto J8B connector on newly installed interface plate 4.1.7.5 DR removes P6A connector from old DBA II using connector tool 4.1.7.6 DR then attaches P6A connector onto J6B connector on newly installed interface plate 4.1.7.7 Repeat installation steps above for other diode box 4.1.7.8 GA moves DR back to tool box 4.1.7.9 DR replaces its tool Hazards: 4.1 a) Service for battery augmentation unsuccessful Causes: - specifics below Control: - continue using old battery source on HST 4.1.1 a) GA does not deploy (same as 1.1(a)) 4.1.4 a) Conduit does not deploy Causes: - mechanical failure (door doesnt open), communication not sent Control: - try opening physically with GA, 3.1(b) 4.1.5.1 a) GA maneuvers DR into colliding with HST Causes: - incorrect positioning; cameras malfunctioning Control: - autonomous monitoring of GA movements via camera and on-board processor to detect if it comes within range of collision with another object, and prevents it from occurring; use other cameras to guide arm (i.e. pan-and-tilt on arm) 4.1.5.3 a) DR breaks connector interface plate on conduit Causes: - tool that grabs plate grips too hard (mechanical) Controls: - pressure sensors on DR grapple fixture, robust tools b) DR collides with interface plate (same as 4.1.5.1(a)) 4.1.5.4 a) GA maneuvers DR into colliding with HST (same as 4.1.5.1(a)) 4.1.5.6 a) GA maneuvers DR into colliding with HST (same as 4.1.5.1(a)) 4.1.5.7 a) DR drops tool floating in free space Causes: - misalignment by tele-operator when replacing tool Control: - autonomous monitoring of DR movements via camera and on-board processor to have an automated closed-loop control system for replacing tools; if tool is dropped and free floating, have tele-operator from ground catch it with DR 4.1.6.2 a) GA maneuvers DR into colliding with HST (same as 4.1.5.1(a)) 4.1.6.3 a) GA maneuvers DR into colliding with HST (same as 4.1.5.1(a)) 4.1.6.5 a) the harness is incorrectly attached, damaging HST hull Causes: - operator error Controls: - cameras and multiple operators on duty to ensure no major errors b) GA maneuvers DR into colliding with HST (same as 4.1.5.1(a)) 4.1.6.6 a) DR loses track of line (i.e. lets go of line) Causes: - operator error; not tight enough grip from tool Controls: - tele-operation to pick up the line again 4.1.6.10 a) DR drops tool floating in free space (same as 4.1.5.7(a)) 4.1.7.2 a) GA maneuvers DR into colliding with HST (same as 4.1.5.1(a)) 4.1.7.3 a) DR cannot remove P8A connector from old connector interface Causes: - wrong tool; connector fused to interface

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- operator chooses correct tool; attempt to repair connector, if not, continue using old power supply 4.1.7.4 a) P8A accidentally attached to wrong interface Causes: - same fitting plugs Controls: - make different connectors have different physical connections 4.1.7.9 a) DR drops tool floating in free space (same as 4.1.5.7(a))

Controls:

4.2

Change-out for WFC3 4.2.1 GA deployed and DR removed (4.1) 4.2.2 Install new ground strap temp stow fixture 4.2.2.1 Cargo bay with temp stow fixture opens 4.2.2.2 GA guides DR to bay 4.2.2.3 DR grabs temp stow fixture with 1 hand 4.2.2.4 DR releases stow fixture from bay attachments with other hand (7/16 hex interface) 4.2.2.5 DR removes temp stop fixture from cargo bay (linear retraction) 4.2.2.6 GA brings DR and temp stow fixture to handrail above WFC 4.2.2.7 DR places temp stow fixture on handrail 4.2.2.8 DR attaches temp stow fixture to handrail 4.2.2.9 GA backs away from workspace 4.2.3 Install WF/PC II Interface Plate 4.2.3.1 GA moves DR back to cargo bay 4.2.3.2 DR removes 3 guide studs securing WF/PC II interface plate in cargo bay 4.2.3.3 DR grabs WF/PC II interface plate with 1 arm 4.2.3.4 DR removes last guide stud securing WF/PC II interface plate 4.2.3.5 DR removes WF/PC II plate from bay 4.2.3.6 GA moves DR + plate to WF/PC II location 4.2.3.7 DR places WF/PC II plate in position with guide studs (using 1 arm) 4.2.3.8 DR attaches WF/PC II plate with 1 guide stud using other arm 4.2.3.9 DR releases WF/PC II plate from grip 4.2.3.10 DR secures WF/PC II plate in position with other 3 guide studs 4.2.3.11 GA backs DR away from workspace 4.2.4 Release blind mate connecter on WF/PC II 4.2.4.1 GA moves DR to blind mate connector 4.2.4.2 DR releases blind mate connector 4.2.4.3 GA backs DR away from workspace 4.2.5 Release ground strap and install on temp stowage fixture 4.2.5.1 GA moves DR to WF/PC II ground strap 4.2.5.2 DR grabs ground strap with 1 hand 4.2.5.3 DR releases ground strap from WF/PC II 4.2.5.4 DR pulls ground strap away from WF/PC II 4.2.5.5 GA + DR move ground strap to temp stow fixture 4.2.5.6 DR places ground strap in proper location on temp stow fixture with 1 arm 4.2.5.7 DR secures ground strap to temp stow fixture with other arm 4.2.5.8 GA + DR back away from workspace 4.2.6 Release A-Latch 4.2.6.1 GA moves DR to A-latch position on WF/PC II 4.2.6.2 DR grabs WF/PC II via WF/PC II interface plate with 1 arm 4.2.6.3 DR releases A-latch with other arm 4.2.7 Remove and stow WF/PC II 4.2.7.1 DR + GA linearly retract the WF/PC II from telescope 7.5 ft 4.2.7.2 DR + GA move WF/PC II to the temp stow fixture 4.2.7.3 DR place WF/PC II on the temp stow fixture with 1 arm 4.2.7.4 DR attaches WF/PC II on the temp stow fixture with A-latch with other arm 4.2.7.5 Back away from workspace 4.2.8 Retrieve WFC3 and begin translation to HST

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4.2.8.1 Move DR+ GA to cargo bay 4.2.8.2 Thermal contamination cover is retracted from WFC3 4.2.8.3 DR is moved to WFC3 ground strap 4.2.8.4 DR grabs ground strap with 1 arm and releases ground strap with the other 4.2.8.5 DR moves ground strap to cargo bay storage fixture with 1 arm and attaches it with the other 4.2.8.6 DR grabs WFC3 with 1 arm 4.2.8.7 DR releases A-latch with other arm 4.2.8.8 DR + GR linearly retract WFC3 7.5 ft from cargo bay of HRV 4.2.8.9 DR_GA move WFC3 to WFC empty space 4.2.9 DR+GA move WFC3 into empty telescope space on HST (may require stabilization from 2nd arm) 4.2.10 Once WFC3 is in place, DR drives A-latch with 1 arm 4.2.11 Re-install ground strap onto WFC3 4.2.11.1 DR grabs ground strap with 1 arm from temp stow fixture 4.2.11.2 DR places ground strap on WFC3 with 1 arm and secures it with the other 4.2.12 DR engages blind-mate mechanism 4.2.13 Detector vent valves (2) opened by solenoid values 4.2.14 Final stow of WF/PC II 4.2.14.1 DR+GA move to WF/PC II 4.2.14.2 DR grabs WF/PC II interface plate with 1 arm 4.2.14.3 DR releases WF/PC II A-latch with other arm 4.2.14.4 DR + GA linearly retract WF/PC II 4.2.14.5 DR+ GA move WF/PC II to cargo bay WFC3 empty storage space 4.2.14.6 DR secures WF/PC II via A-latch

Hazards: 4.2.2.2 a) GA maneuvers DR towards EM cargo bay and collides with EM (same as 4.1.5.1(a)) 4.2.2.4 a) DR accidentally lets go of stow fixture free floating (same as 4.1.5.7(a)) 4.2.2.6 a) GA and DR hits WFC (same as 4.1.5.1(a)) 4.2.3.1 a) GA maneuvers DR towards EM cargo bay and collides with EM (same as 4.1.5.1(a)) 4.2.3.4 a) DR loses guide studs free floating in space Causes: - misuse of tool Controls: - ensure tool secures studs; also, have spare studs available in tool shed 4.2.3.7 a) DR+ plate collide with WF/PC II (same as 4.1.5.1(a)) Controls: - continue removal process regardless of damage to WF/PC II since it will be disposed anyway 4.2.4.1 a) GA + DR accidentally hits HST (same as 4.1.5.1(a)) 4.2.5.1 a) GA and DR hits WFC (same as 4.1.5.1(a)) 4.2.5.5 a) DR loses ground strap in transit free floating in space Causes: - misuse of tool Controls: - ensure tool has strong grip; have spare straps available in tool shed 4.2.6.1 a) GA and DR hits WFC or HST (same as 4.1.5.1(a)) 4.2.6.3 a) two arms on DR collide Causes: - operator error Controls: - use cameras and closed feedback-loop to prevent collision; internal positioning software should be aware of location of other arm and no allow actions to result in collision 4.2.7.1 a) GA + DRs retraction not completely linear and end up hitting HST sides Causes: - mechanical jerk in joints causing deviation; operator error Controls: - do simulations to check for issues before performing actual task; use cameras on DR to guide WF/PC II out slowly 4.2.7.2 a) GA + DR collides with EM (same as 4.1.5.1(a)) 4.2.8.1 a) GA + DR collides with EM (same as 4.1.5.1(a)) 4.2.8.2 a) Thermal cover removal damages WFC3 Causes: - cover scrapes camera lens; WFC3 is jostled and mechanically damaged Controls: - make sure covering is soft inside (i.e. Styrofoam inner layer), and flexible; have DR move slowly such that no sudden jerks will hurt WFC3

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b) DR hits WFC3 Causes: - operator error; mechanical jerk in joint Controls: - do practice and simulations before hand to test operator and DR; use cameras on DR to carefully remove covering 4.2.8.5 a) DR loses ground strap in transit free floating in space (same as 4.2.5.5(a)) 4.2.8.8 a) DR+ GA does not perform completely linear retraction resulting in collision of WFC3 and EM cargo bay sides (same as 4.2.7.1(a)) 4.2.9 a) DR+GA inexact causing WFC3 to collide with HST (same as 4.1.5.1(a)) Controls: - also move slowly such that if a collision occurs, itll be a non-damaging nudge 4.2.10 a) DR hits WFC3 (same as 4.2.8.2(b)) 4.2.13 a) Detector vent valves not opened Causes: - mechanical, communication Controls: - same as 4.1.4 (a) 4.2.14 a) GA + DR holding WF/PC II collides with EM cargo bay (same as 4.1.5.1(a)) Controls: - can also have foam lining inside of cargo bay b) WF/PC II not completely secure in storage area Causes: - operator error; missing parts (pins/bolts/straps/latches) Control: - multiple operators to watch; spare parts in tool shed 4.3 Change-out for RSU 4.3.1 Move DR to conduit/ECU end 4.3.2 DR grabs conduit/ECU end 4.3.3 DR moves it to circular connector interface on WFC3 4.3.4 DR attaches conduit/ECU end to circular connector interface on WFC3 4.3.5 DR opens bay 1 door 4.3.6 DR removes terminator plug on 486 (59) 4.3.7 DR places terminator plug in HRV cargo bay 4.3.8 DR grabs RSU 1553 bus end 4.3.9 DR moves it to bay 1 of HST 4.3.10 DR connects RSU 1553 bus end to 59 4.3.11 DR closes Bay 1 Hazards: 4.3.1 a) DR hits HST (same as 4.1.5.1(a)) 4.3.3 a) DR hits WFC3 (same as 4.2.8.2(b)) 4.3.5 a) DR hits EM (same as 4.1.5.1(a)) b) Door doesnt open Causes: - problems with joint; something blocking path of door Controls: - make sure everything is well oiled; remove the entire door if necessary and replace it afterward 4.3.6 a) Collision with processor (same as 4.1.5.1(a)) 4.3.7 a) DR hits EM (same as 4.1.5.1(a)) 4.3.9 a) DR hits HST (same as 4.1.5.1(a)) 5. EM Jettison & Disposal 5.2 DR back in stow-away position inside isolated cargo bay 5.3 GA folds back to original tie-down position in EM cargo bay 5.4 Ground control sends signal for EM to detach from DM 5.5 EM performs evasive maneuvers to navigate away from HST 5.6 EM performs de-orbit burns to re-enter and burn up in atmosphere along with GA and DR

Hazards: 5.1 a) DR cannot be retracted to original position Causes: - damage during operation Control: - make sure there is some margin of space for error in cargo bay b) DR not secured

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5.2

Causes: - missing (bolts/pin/straps); original padding misaligned Control: - spare parts in tool shed; not too urgent since it will be burned up anyway a) Same as 5.1(a) and (b)

A3: RS 422 SPECIFICATIONS


SPECIFICATIONS Mode of Operation Total Number of Drivers and Receivers on One Line Maximum Cable Length Maximum Data Rate Maximum Driver Output Voltage Driver Output Signal Level (Loaded Min.) Driver Output Signal Level (Unloaded Max) Driver Load Impedance (Ohms) Max. Driver Current in High Z State Max. Driver Current in High Z State Slew Rate (Max.) Receiver Input Voltage Range Receiver Input Sensitivity Receiver Input Resistance (Ohms) RS423 SINGLE ENDED 1 DRIVER 10 RECVR 4000 FT. 100kb/s +/-6V +/-3.6V +/-6V >450 N/A +/-100uA Adjustable +/-12V +/-200mV 4k min. RS422 DIFFERENTIAL 1 DRIVER 10 RECVR 4000 FT. 10Mb/s -0.25V to +6V +/-2.0V +/-6V 100 N/A +/-100uA N/A -10V to +10V +/-200mV 4k min.

Loaded Unloaded Power On Power Off

Wires for an RS 422 Line: RS422 Rx Gnd RS422 Rx +ve RS422 Rx -ve RS422 Tx +ve RS422 Tx -ve RS422 Tx Gnd From Reference A [2] 1 2 3 4 5 6

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A4: MIL-STD-1553B SPECIFICATIONS


Data rate: 1 Mbps Encoding: Manchester II bi-phase level Transmission medium: Twisted, shielded pair Cable characteristic impedance: 70 to 85 ohms Topology: linear, multidrop bus Maximum number of bus connections (including bus controller): 30 Maximum stub length from bus to electronic units: 1 ft (direct coupled), 20 ft (transformer coupled) Failure tolerance: ISS uses two buses in a Dual Redundant arrangement (recommended configuration) and all transformer coupled stubs Word formats for MIL-STD-1553B communications:
Bit Times Command Word
Sync

6 7

9 10 11 12 13 14 15 16 17 18 19 20
T/R Subaddress/Mode Data Word Count/Mode Code Parity

Remote Terminal Address

Data Word
Sync

Data

Parity

Status Word
Sync

Remote Terminal Address

Reserved

Parity

- Message Error - Instrumentation - Service Request

T/R = Transmit/Receive

Broadcast Command Received Busy Subsystem Flag Dynamic Bus Control Acceptance Terminal Flag

= logic '0' = logic '1'

From Reference A [3]

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A5: DR STOPPING CALCULATIONS


Stopping Requirement: Stop 1000 lbm within 2 in m = 1000lbm = 454.5 kg d = 2 in =0.0508 m DR arm length = 8 ft L=8 ft = 2.438 m Let deceleration be 2 in/s^2 a = -2 in/s^2 = 0.0508 m/s^2 F = m*a = 454.5 * 0.0508 =23.19 N T = F*L =23.19 * 2.438 =56.3 Nm

A6: REFERENCES
[1] [2] [3] Parrish, Joseph C., Ranger Telerobotic Shuttle Experiment (RTSX): Status Report, Washington, D.C. Arc Electronics, RS422 Balanced Differential Drivers, http://www.arcelect.com/rs422.htm Gillet, Ross, Electrical_Systems_Notes_UofT2004, 2004

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Appendix B
B1: TORQUE CALCULATIONS
Torque and Power calculations for moving DR+WFC
Moment of Inertia of GA+DR+WFC with respect to GA shoulder joint I = [1/3(Mass of GA) x (Length of GA)2] + [(Mass of DR) x (1/2 Length of DR+Length of GA) 2 ] + [(Mass of WFC) x (Length of DR + Length of GA) 2] I= [1/3 x 600kg x (10m) 2] + [(300kg) x (1/2 x 2.1m + 10m)2] + [(454kg) x (2.1 + 10m) 2] = 86470 kg*m2 Torque = Moment of Inertia (I) x Angular Acceleration Torque = 86470 kg*m2 x 0.0006 rad/s2 = 51.88 (kg*m2) / s2 Power = Torque x Angular Velocity Power = 51.88 (kg*m2) / s2 x 0.006 rad/s = 0.31 Watts

Torque and Power calculations for stopping HST


M = 11110 kg (24500 lb) h = 13.2 m (43.5 ft) R = 2.1 m (7 ft) w = 0.22 deg/s = 3.84e-3 rad/s in the x, y, z directions t = est. time to slow HST to zero = 10 s Moment of inertia matrix for HST: 1 1 2 2 0 0 12 Mh + 4 MR 0 0 173566 1 1 2 2 = 0 0 0 173566 0 I= Mh + MR 12 4 0 24498 0 1 2 0 0 MR 2 Angular acceleration of HST: w 3.84 103 a= = = 3.84 104 rad / s 2 for all 3 axes => a = [3.84 3.84 3.84]Te-4 t 10 Torque of HST (which is applied to the grapple arm as the GA brings HST to a stop): x 66.6 = Ia = y = 66.6 Nm || = (66.6^2 + 66.6^2 + 9.41^2) = 94.7 Nm 9.41 z

Power = Torque x Angular Acceleration Power = (66.6*3.84e-3) + (66.6*3.84e-3) + (9.41*3.84e-3) = 0.5476224 Watt

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B2: TORQUE & POWER REQUIRED FOR SNARE MOTORS

h=40 cm

N T

p=27cm

End Effector N Grapple Probe max

R=18.5cm The normal force exerted on the grapple probe on the HST grapple fixture must be enough to make sure that the GA EE does not tip when the maximum torque is applied at its end (i.e. the torqure required to stop the HST).
Thus = N*R => N = /R = 94.7 Nm / 0.185m = 511.9 Newtons

R=18.5cm h-p=13cm = 55 degrees = 0.96 radians

tan = 18.5/13

There are 3 snare wires, each experiencing tension T in its wire. Thus T = N/(6*cos) = 511.9 / 3.44 = 148.7 Newtons Since 3 ends of the snare are attached to the rotating outer cup, controlled by the snare motor, the total force exerted on the cup, and thus the motor, is 3T. Based on Canadarms performance, velocity v is estimated to be V = 2R*(0.96) m / 10s = 0.0355 m/s = 1.8 rpm Power = Force x Velocity = 3T x 0.0355 = 15.84 Watts Torque = Force x Displacement = 3T x 0.355 = 158.4 Nm

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B3: SPEED REQUIREMENT CALCULATIONS

128

B4: GA BOOM ANALYSIS

129

B5: HST CAPTURE SCENARIO ANALYSIS

130

131

B6: HEAT TRANSFER


Conduction
Heat conduction through a solid is governed by its conductivity, surface area, and its temperature gradient. The rate of heat conduction is governed by the equation:

where q is the conduction heat flow in Watts, a the surface area, k is the thermal conductivity of the material, Dx is the thickness, and DT is the difference in temperature across the material.

Radiation and Absorption


For diffuse or Lambertian surfaces, heat emitted into space is modelled as proportional to that radiated by a perfect radiator or blackbody. The emitted energy is:

W/m^2/K^4 is the Stefanwhere e is the surface emissivity of the material, Boltzmann constant, A the surface area, and Ts and Ta are the absolute temperature of the surface and the ambient environment respectively. The vacuum of space is equivalent to an ambient temperature of 3K. The absorbed energy is given by the product of the incident energy G, the surface area a, and the material absorptivity constant for the material a. The incident heat energy for objects in Earth orbit directly exposed to solar radiation is 1358 Watts/m^2. The equilibrium temperature of a planar surface exposed to solar flux can be calculated by setting the absorbed energy equal to the emitted energy and solving for temperature T.

Convection
Due to the lack of atmosphere, there is no convective heat transfer between a space system and its environment.

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B7: REFERENCES
[1] http://www.mpm.maxonmotor.com/files/catalog/2004/pdf/04_169_e.pdf [2] http://www.mpm.maxonmotor.com/files/catalog/2004/pdf/04_223_e.pdf [3] http://www.mpm.maxonmotor.com/files/catalog/2004/pdf/04_224_e.pdf [4] http://www.mpm.maxonmotor.com/files/catalog/2004/pdf/04_213_e.pdf [5] http://www.islandone.org/ISDC/ISDC1999_Houston/ISDC99Abstracts_CD/AIAA%20Papers/ISS%20Operations%20for%20the%20SPDM.pdf

[6] http://www.shirleysbay.com/Articles/canadarm2.htm
[7] http://www.ueet.nasa.gov/elements.htm#aluminum [8] http://www.tms.org/pubs/journals/JOM/0104/Rawal-0104.html

[9] http://alphagetriebe.de/en/170_194.htm [10] http://ranier.oact.hq.nasa.gov/telerobotics_page/Technologies/0224.html


[11] http://www.sciencedaily.com/encyclopedia/lidar [12] http://www.mpm.maxonmotor.com/files/catalog/2004/pdf/04_184_e.pdf [13] http://www.globalsecurity.org/military/systems/ground/gltd.htm [14] http://www.amci.com/resolvers/resolvers.ht20.asp

[15] http://www.prosecuritywarehouse.com/PDFs/WV-NS324.pdf [16] http://www.deepsea.com/led_multiseacam.html [17] http://www.ddiglobal.com/solutions/time_critical_guidelines.cfm [18] http://www.dupont.com/kapton/general/spphythe.html [19] http://www.analog.com/UploadedFiles/Data_Sheets/212087079AD2S80A_b.pdf
[20] http://www.aerogel.com/pdfs/spaceloftar3100tds.pdf

[21] http://www.bwantennas.com/pro/wire.pro.htm#coax
[22] http://www.rs485.com/rs485spec.html

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Appendix C
C1: CABLING MASS CALCULATIONS
Data Lines:

Main Data Line


Dual Redundant MIL-STD-1553B 2 wires (x2(redundancy)) (~0.9A) implement M22759-11-28-* AWG 28 (1.3A max) density = 1.36lbs/1000ft = 0.002023 kg/m Length of each wire = length of boom + 2 m*num of joints + length of EE Length of each wire = 11m + 12m + 1m = 24 m Total mass of main data lines = 24m * 2*2 * 0.002023kg/m = 0.1942 kg

For DR
Dual Redundant RS-422 6 wires (x2(redundancy)) (~.1mA) implement M22759-11-28-* AWG 28 (1.3A max) density = 1.36lbs/1000ft = 0.002023 kg/m Length of each wire = length to EM + length of boom + 2 m*num of joints + length of EE Length of each wire = 1m + 11m + 12m + 1m = 24 m Total mass of DR data lines = 25m * 6*2 * 0.002023kg/m = 0.6069kg

GA/EM Connection
Dual Redundant RS-422 6 wires (x2(redundancy)) (~.1mA) implement M22759-11-28-* AWG 28 (1.3A max) density = 1.36lbs/1000ft = 0.002023 kg/m Length of each wire = 1m Total mass of GA/EM data lines = 1m * 6*2 * 0.002023kg/m = 0.0243kg
Power Lines:

Main Power Line


2 wires (x2(redundancy)) (I = P/V = 210/28 = 7.5A) implement M22759-11-18-* AWG 18 (9.2A max) density = 8.14lbs/1000ft = 0.01212 kg/m

134

Length of each wire = length of boom + 2 m*num of joints + length of EE Length of each wire = 11m + 12m + 1m = 24m Total mass of main power lines = 24m * 2*2 * 0.01212kg/m = 1.1635kg

For DR
2 wires (x2(redundancy)) (I = P/V = 210/28 = 7.5A) implement M22759-11-18-* AWG 18 (9.2A max) density = 8.14lbs/1000ft = 0.01212 kg/m Length of each wire = length to EM + length of boom + 2 m*num of joints + length of EE Length of each wire = 1m + 11m + 12m + 1m = 25m Total mass of DR power lines = 25m * 2*2 * 0.01212kg/m = 1.212kg

GA/EM Connection
2 wires (x2(redundancy)) (I = P/V = 210/28 = 7.5A) implement M22759-11-18-* AWG 18 (9.2A max) density = 8.14lbs/1000ft = 0.01212 kg/m Length of each wire = 1m Total mass of GA/EM power lines = 1m * 2*2 * 0.01212kg/m = 0.0485kg
Video Lines

Boom Camera
1 cable (x2(redundancy)) 50-ohm coaxial cable density = 4lbs/100ft = 0.05971kg/m Length of each cable = length of boom Length of each cable = 5.5m Total mass of boom camera video lines = 5.5m * 1*2 * 0.05971kg/m = 0.6569 kg

EE Camera
1 cable (x2(redundancy)) 50-ohm coaxial cable density = 4lbs/100ft = 0.05971kg/m Length of each cable = length of boom + 2 m*num of joints + length of EE Length of each cable = 11m + 12m + 1m = 24m Total mass of boom camera video lines = 24m * 1*2 * 0.05971kg/m = 2.8661 kg 135

Joint ECUs (x6 x2(redundancy))


AWG 18: AWG 28: 2 power in 8 motor 12 resolver 4 RDC 2 Brake 2 data 4 resolver 4 RDC (0.3m) (0.3m) (0.6m) (wires may be wound during joint movement) (0.6m) (0.6m) (0.3m) (0.6m) (0.6m)

Total mass Joint ECU lines = 12 * (46 * 0.3m * 0.01212 kg/m + 18 * 0.3m * 0.002023 kg/m) = 2.1387kg

EE ECU (x2(redundancy))
AWG 18: AWG 28: 2 power in (0.3m) 8 plug1 motor (0.75m) 12 resolver (plug1 motor) (0.75m) 4 RDC (plug1 motor) (0.75m) 2 Brake (plug1 motor) (0.75m) 8 plug2 motor (0.75m) 12 resolver (plug2 motor) (0.75m) 4 RDC (plug2 motor) (0.75m) 2 Brake (plug2 motor) (0.75m) 8 snare motor (0.75m) 12 resolver (snare motor) (0.75m) 4 RDC (snare motor) (0.75m) 2 Brake (snare motor) (0.75m) 2 camera (0.75m) 2 LED (0.75m) 2 LRF (0.75m) 2 Force/Torque Sensor (0.75m) 2 A/D Converter (0.75m) 2 data 4 plug1 res. 4 plug1 RDC 4 plug2 res. 4 plug2 RDC 4 snare res. 4 snare RDC 2 LRF 2 A/D Converter (0.3m) (0.5m) (0.5m) (0.5m) (0.5m) (0.5m) (0.5m) (0.5m) (0.5m)

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Total mass EE ECU lines = 2*(66.6m*0.01212 kg/m + 14.6m*0.002023 kg/m) = 1.6735 kg

Boom Camera ECU (x2(redundancy))


AWG 18: AWG 28: 2 power in (0.3m) 8 camera 1 pan motor (0.3m) 12 resolver (camera 1 pan motor) (0.5m) 4 RDC (camera 1 pan motor) (0.5m) 2 Brake (camera 1 pan motor) (0.5m) 8 camera 1 tilt motor (0.3m) 12 resolver (camera 1 tilt motor) (0.5m) 4 RDC (camera 1 tilt motor) (0.5m) 2 Brake (camera 1 tilt motor) (0.5m) 8 camera 2 pan motor (0.3m) 12 resolver (camera 2 pan motor) (0.5m) 4 RDC (camera 2 pan motor) (0.5m) 2 Brake (camera 2 pan motor) (0.5m) 8 camera 2 tilt motor (0.5m) 12 resolver (camera 2 tilt motor) (0.5m) 4 RDC (camera 2 tilt motor) (0.5m) 2 Brake (camera 2 tilt motor) (0.5m) 2 camera1 (0.5m) 2 LED (0.5m) 2 camera2 (0.5m) 2 LED (0.5m) 2 data 4 camera1 pan res. 4 camera1 pan RDC 4 camera1 tilt res. 4 camera1 tilt RDC 4 camera2 pan res. 4 camera2 pan RDC 4 camera2 tilt res. 4 camera2 tilt RDC (0.3m) (0.5m) (0.5m) (0.5m) (0.5m) (0.5m) (0.5m) (0.5m) (0.5m)

Total mass Boom Camera ECU lines = 2*(55.25m*0.01212 kg/m + 16.6m* 0.002023 kg/m) = 1.4064 kg
Total mass of wires = 10.557kg

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C2: REFERENCES
[1] http://www.amci.com/resolvers/resolvers.ht20.asp [2] http://ams.aeroflex.com/ProductFiles/DataSheets/RDCDatasheet.pdf [3] http://www.salvagetech.com/datasheets/ab_pot.pdf [4] http://www.anafaze.com/products/heaters/ht_flex.cfm [5] http://www.thermalswitch.com/docs/ts700b_web.pdf [6] http://www.altaajer.net/cctv__cameras.htm [7] http://www.deepsea.com/led_multiseacam.html [8] http://www.prosecuritywarehouse.com/networkcams.html [9] http://robotics.jpl.nasa.gov/tasks/tmr/papers/LaserRangefinderPaper0900.pdf [10] http://content.honeywell.com/sensing/prodinfo/force/catalog/c15_61.pdf [11] http://www.intel.com/design/intarch/prodbref/272712.htm [12] http://www.mpm.maxonmotor.com/files/catalog/2004/pdf/04_169_e.pdf

[13] http://www.mpm.maxonmotor.com/files/catalog/2004/pdf/04_184_e.pdf [14] http://www.spacedaily.com/news/space-electronics-02b.html

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Appendix D
D1: PRECISION CALCULATIONS
Joints Shoulder Roll -> -180 to +180 deg Pitch -> -90 to +90 deg Elbow Pitch -> -165 to +165 deg Wrist Yaw -> -180 to +180 deg Pitch ->-180 to +180 deg Roll -> -180 to +180 deg Based on a tip precision of 0.16 inches as given in NASAs requirements, we get a precision angle of 0.0187189 degrees For joint precision: 360/0.0187189 = 19232 = 214.2 ~ 215 needs 15 bit precision Camera Resolution: 640x480 Panning Range 360 endless Panning Speed Manual: approx. 1.0/s ~ 100/s, 8-step/64-step Preset position: max. 100/s Tilting Range 0 ~ 92 Tilting Speed Manual: approx. 1.0/s ~ 100/s, 8-step/64-step Preset position: max. 100/s We want a precision of about 2 degrees 360/2 = 180 = 27.5 ~ 28 needs 8 bit precision

Torque Sensor Maximum torque we expect is around 200 Nm We want a precision of about 5 Nm Bits: 200/5 = 40 = 25.3 ~ 26 needs 6 bit precision

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D2: SOFTWARE DESCRIPTION


1. Launch & Pursuit 4.1 GA in tie-down position on EM surface - GA Motion Software continuously monitors, in real time, the tie-down position of the GA to ensure its safe storage through the use of its Position and Attitude Sensors - GA Communication Software sends data to Ground Control if tie-down position has been compromised 1.2 DR in stow-away position inside isolated cargo bay 2 Proximity Operations 2.1 As HRV prepares for capture, power up GA and run system check - At a predetermined distance from the HST, the EM Communications Software powers up the GA. - GA Diagnostic Software performs a self-diagnostic, verifying all communication links, and power levels. The software shall gather the distance information from EM CPU. If GA CPU is unable to receive said information, software shall inform Ground Control and wait for further instructions. - If system diagnostic does not report 100% operating efficiency in the GA, software informs Ground Control and wait for further instructions. 3 Capture 3.1 Release pins/bolts/straps tying GA down (elbow, wrist, shoulder, and end effector tie downs. - EM Software releases all mechanisms (i.e. pins/bolts/straps) that secure the GA. The EM Software activates the mechanisms that perform this operation. - Software detects if any mechanisms were unable to be released from the GA. If so, software informs Ground Control 3.2 GA deploys/unfolds - If all mechanisms are properly released, GA software deploys/unfolds the GA. 3.3 GA runs full system check and functional simulations - GA Diagnostics Software performs self-diagnostic start-up checks: o GA Communications Software confirms communication links open: GA to EM and GA to Ground via EM o GA Motion Software confirms the GA position sensors are providing the correct dormant position readings - GA Diagnostics Software performs Pre-Deployment Checks o GA Communications Software sends Incremental Unfold Command to GA actuators to unfold GA by a small increment o GA Motion Software receives input from GA Joint Sensors to confirm that Unfold Command was issued and executed correctly - GA Diagnostics Software performs full functional test: o GA Communications Software systematically sends Test Jointst Command to GA joint motors to move each joint a small distance then back. GA Diagnostics Software confirms the actual movements are within the normal operating specifications. 3.4 GA assumes ready to capture pose - GA Motion Software places the GA in ready to capture pose where the arm assumes a predetermined configuration to obtain visual contact with HST via the GA camera. 3.5 HRV positions HST GR in Capture Box, allowing GA to acquire the GF target - GA Motion Software begins systematic GA camera sweeping. The GA Motion Software stops the GA camera sweeping when the HST is detected via the time-stamped visual input.

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GA Motion Software begins GA camera scanning of the HST. The GA Communication Software sends the EM software an HST acquired signal once the HST has been acquired. Acquiring the HST involves determining and saving the position, attitude, velocity and rotational velocities of the HST relative to the HRV by interpreting the time-stamped visual input from the GA camera. The GA Motion Software then stops the GA camera scanning of the HST. GA Software determines and save the positions, attitudes, velocities and rotational velocities of both HST grapple fixtures (HST GFs), and both solar arrays. The GA Communications software shall send a capture window found signal after determining and saving the closest 8 minute capture window when an HST GF will stay within capture range and when the solar arrays will not interfere with the GA capture of that HST grapple fixture. If a capture window cannot be found the GA shall send a capture window not found signal to the EM Communications Software and will wait for further instructions.

3.6 Ground Control monitors HST through video, determines HST roll rates and GF capture windows . - Ground control commands the GA camera to track the targeted HST GF (the HST GF accessible in the closest capture window). Ground control sends GA a HST GF target acquired signal when the HST GF has its position, attitude, velocity and rotational velocities determined. 3.7 In a GF capture window Gnd Ctrl adjusts GA position /orientation enabling ready to capture conditions - Ground control tele-robotically sends roll rates to the GA, which is interpreted as joint angle to move the arm until the position/orientation of the GF is aligned with the EE capture box 3.8 Ground Control tele-robotically controls GA EE to surround HST GF 3.8.1 GC adjusts GA so EE cameras target GF - Ground control tele-robotically sends roll rates to the GA, which is interpreted as joint angle to move the arm until the position/orientation of the GF is aligned with the EE capture box 3.8.2 Predictive displays project the current positions of the GA EE and HST GF - Due to the time lag in communications between GA and GC, GC will have software to predict movement and orientation of HST with respect to GA based on previously collected information about HSTs current roll, position and velocity 3.8.3 GC telerobotically uses pan and tilt boom camera to watch for hazards - GC operator keeps track of the pan and tilt camera feeds to ensure it is not in danger. If an obstacle approaches, the operator should see it in the camera with enough time to conduct avoidance maneuvers 3.8.4 GA, telerobotically controlled, keeps GF in view while reaching towards it with GA EE - The ground operator, using prediction software as well as video feed, maneuvers GA to keep track of HST GF 3.8.5 GA EE surrounds HST GF - GA is maneuvered forward such that its EE envelopes HSTs GF 3.9 EE captures HST GF and brings HST to near rest relative to HRV 3.9.1 EE locks with HST GF - GA Communications Software sends a GA EE Ready to Lock signal to the EM software when the GA EE is in mating position with the HST GF using visual data processing and GA position sensor readings. - GA Motion Software activates GA EE / HST GF locking. - GA Software confirms the GA EE / HST GF locked connection with the GA EE sensor data. 3.9.2 HST and HRV relative velocities are brought to rest

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The GA software activates linear deceleration of the GA EE velocity, and rotational velocity to slow the HST relative to the HRV in 10 seconds.

3.10 GA movement enabled to join HRV and HST modules together - GA Motion Software activates and controls the movement of the GA such that the HRV + EM are placed directly under the HST Aft Shroud Bulkhead with the EM docking latches aligned with the HST berthing pins. The GA software checks the GA sensors every 1 second to confirm proper GA movement. - GA Motion Software confirms, using GA position sensor data and DM video data that the GA has aligned the EM docking latches with the HST berthing pins. The GA software activates and controls the linear movement joining the EM docking latches and the HST berthing pins. The GA software stops GA movement when the DM has been moved to joining position. The EM verifies with the EM software that the docking latches have connected to the berthing pins. 3.11 GA releases HST GF and folds up to dormant position - GA Motion Software activates the GA EE release of the HST GF. The GA software confirms the GA EE release through the GA EE sensors. - GA Motion Software activates and controls the linear retraction of the GA EE from the HST GF 0.5m. The GA Motion Software then confirms the position of the GA. The GA Motion Software controls the movement of the grapple arm into the folded dormant position. 4 Servicing General operations of GA and DR that are performed repeatedly for each service task is outlined in detail below (4a and 4b) and referenced thereafter 4a GA takes out DR to perform servicing operations Common Functions Required from GA and DR When Servicing 4a GA takes out DR to perform servicing operations 4a.1 GA deploys/unfolds from dormant position - GA Communications Software receives Initialize Command from Ground Control via EM Communications Software - GA Diagnostics Software performs Start-Up Checks o GA Communications Software confirms communication links open: GA to EM and GA to Ground via EM o GA Motion Software confirms the GA position sensors are providing the correct dormant position readings - GA Diagnostics Software performs Pre-Deployment Checks o GA Communications Software sends Incremental Unfold Command to GA actuators to unfold GA by a small increment o GA Motion Software receives input from GA Joint Sensors to confirm that Unfold Command was issued and executed correctly - GA Motion Software plots a path to unfold GA such that GA does not come into contact with HST - GA Communications Software sends Unfold Command to GA - GA Motion Software receives and processes input from GA Joint Sensors to ensure that GA does not contact HST - GA Diagnostics Software performs Joint Checks o GA Communications Software sends Incremental Rotate Command to GA actuators to rotate GA joint by a small increment o GA Motion Software receives input from GA Joint Sensors to confirm that Rotate Command was issued and executed correctly o Process repeats for each GA joint - GA Communications Software sends Arm Deployed Message to Ground Control via EM Communications Subsystem 4a.2 DR cargo bay door open via ground control

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GA Communications Software receives DR Door Open Message from Ground Control via EM Communications Subsystem

4a.3 GA uses cameras to locate the electro-mechanical grapple fixture (EMGF) on DR - GC moves the GA camera to view predicted EMGF position - GA Software processes visual data to locate EMGF 4a.4 Predictive displays project the current positions of GA EE and DR EMGF - GCs Motion Software predicts the current positions based on data it has collected by observing the environment - GC adjusts the GA and GA EE position to match preset initial EMGF capture position. - GA Software processes visual data confirm EMGF is within the target capture box - Tele-operator adjusts the GA EE to its capture attitude corresponding to the current EMGF attitude. 4a.5 GA, telerobotically controlled, keeps DR EMGF in view while reaching towards it with GA EE - Tele-operator shall move and orient the GA body normal to ( 45) and away from the surface of the HST, to prevent contact with the HST. - GA Motion Software shall check GA sensor data to monitor for contact between GA and HST. 4a.6 GAs EE captures DRs EMGF - GC Tele-operator moves GA EE closer to the HST GF at 2cm/s max relative to HST. - GC Motion Software predicts GA and GA EE position, attitude and velocity, and rotational velocity every 0.5 sec using GA position sensor data. - GA Software determines and saves the position of the EMGF every 0.5 sec - GA Motion Software limits the speed of the GA EE to 0.1m/s relative to HST within 0.15m of the HST - GA Motion Software stops the GA EE motion when the GA EE is in locking position with the EMGF. - GA Software enables the mechanical power and communication link to join with DR. - GA Software sends GA and DR Linked Message to the EM Communication Software. 4a.7 GA connection allows DR to power up - GA Power Software sends DR Power Connect Command to GA Power Control Systems hardware to initiate link to DR Power Control System - GA Power Software receives, processes and monitors voltage and power readings from GA and DR Power Control Systems hardware 4a.8 Release pins/bolts/straps on launch locks holding DR down - GA Communications Software receives Unlocked Message from DR Communications Software via EM Communications Software 4a.9 GA maneuvers DR out of cargo bay 4a.9.1 GA uses inlaid dead-reckoning system to pull DR straight out 4a.9.2 GA verifies that with pan-and-tilt camera system 4a.10 DR unfolds in space and does a full system check 4b GA maneuvers DR to the tools, and the tool for attaching conduit to diode boxes attached to DR - GA Motion Software plots a path to move GA to EM Cargo Bay such that neither GA nor DR makes contact with HST or HRV. - GA Communications Software sends Move to Tools Command to GA to move GA and DR to Cargo Bay - GA Motion Software receives input from GA Joint Sensors to ensure that GA and DR do not come into contact with HST or HRV. 4b.6 Ground station selects the desired tool 4b.7 DR positions cameras in the vicinity of the desired tool 4b.8 Image data transferred to ground

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4b.9 DR moves automatically to position itself over the desired tool 4b.10 Operator confirms position of DR and : 4b.10.1 triggers next move in auto mode 4b.10.2 opts for another image capture 4b.10.3 manually adjusts the tip position 4b.6 DRs EE locks with tool and withdraws it from its compartment 4.2 Conduit Deploy/ Battery Augmentation 4.2.1 GA deploys/unfolds - See 4a.1 4.2.2 GA takes out DR to perform servicing operations (4a)

4.2.3 GA maneuvers DR to the tools, and gets the diode box assemblies II (DBA II) handle clamp tool for attaching conduit to diode boxes in 1 hand (4.2) - GA Motion Software plots a path to move GA to EM Cargo Bay such that neither GA nor DR makes contact with HST or HRV. - GA Communications Software sends Move to Tools Command to GA to move GA and DR to Cargo Bay - GA Motion Software receives input from GA Joint Sensors to ensure that GA and DR do not come into contact with HST or HRV. 4.2.4 Deploy conduit from DM 4.2.4.1 Cargo bay door containing conduit is opened 4.2.4.2 Conduit is partially ejected a set amount from its holding bay 4.2.5 Make connector interface plate attachment 4.2.5.1 GA maneuvers DR close to conduit end connecter interface plates - GA Motion Software plots a path to move GA to conduit interface plates on DM such that neither GA nor DR makes contact with HST or HRV. - GA Communications Software sends Move to Conduit Command to GA to move GA and DR to interface plates - GA Motion Software receives input from GA Joint Sensors to ensure that GA and DR do not come into contact with HST or HRV. 4.2.5.2 Ground operator uses cameras to determine how DR should capture the plate 4.2.5.3 DR grabs one DBA II connector interface plate (-V2 or +V2) from conduit in free hand 4.2.5.4 GA maneuvers DR with DBA connector in hand up to HST DBA II handle - GA Motion Software plots a path to move GA to DBA II handle on HST such that neither GA nor DR makes contact with HST or HRV. - GA Communications Software sends Move to DBA II Command to GA to move GA and DR to DBA II handle - GA Motion Software receives input from GA Joint Sensors to ensure that GA and DR do not come into contact with HST or HRV. 4.2.5.5 Install connector interface plate on DBA II handle with DRs DBA II handle clamp on EE 4.2.5.6 GA moves DR to tool box and DR puts tool back in its box - GA Motion Software plots a path to move GA to EM Cargo Bay such that neither GA nor DR makes contact with HST or HRV. - GA Communications Software sends Move to Tools Command to GA to move GA and DR to Cargo Bay - GA Motion Software receives input from GA Joint Sensors to ensure that GA and DR do not come into contact with HST or HRV. 4.2.6 Attach harnesses to HST handrails 4.2.6.1 DR gets harness attachment tool for attaching harness to HST handrails (4.2) 4.2.6.2 GA maneuvers DR to harness

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GA Motion Software plots a path to move GA to harness such that neither GA nor DR makes contact with HST or HRV. - GA Communications Software sends Move to Harness Command to GA to move GA and DR to harness - GA Motion Software receives input from GA Joint Sensors to ensure that GA and DR do not come into contact with HST or HRV. 4.2.6.3 DR uses free hand to grab harness, starting from the edge of the conduit 4.2.6.4 Ground operator uses cameras to position harness against HST handles 4.2.6.5 DR attaches the harness with its tool 4.2.6.6 DRs free hand moves along the line to the next position 4.2.6.7 Again, DR attaches harness to indicated handrails using harness attachment tool 4.2.6.8 Repeat attaching harness to handrails (4 places for V2 and 8 places for + V2) 4.2.6.9 GA moves DR to tool box - GA Motion Software plots a path to move GA to EM Cargo Bay such that neither GA nor DR makes contact with HST or HRV. - GA Communications Software sends Move to Tools Command to GA to move GA and DR to Cargo Bay - GA Motion Software receives input from GA Joint Sensors to ensure that GA and DR do not come into contact with HST or HRV. 4.2.6.10 DR puts tool back in its box 4.2.7 Connect batteries to HST Diode Box Assemblies II (DBA II) 4.2.7.1 DR gets DBA II connector tool (4.2) 4.2.7.2 GA maneuvers DR to HST diode box - GA Motion Software plots a path to move GA to HST Diode Box such that neither GA nor DR makes contact with HST or HRV. - GA Communications Software sends Move to Diode Box to GA to move GA and DR to Diode Box - GA Motion Software receives input from GA Joint Sensors to ensure that GA and DR do not come into contact with HST or HRV. 4.2.7.3 DR removes P8A connector from old DBA II using connector tool 4.2.7.4 DR then attaches P8A connector onto J8B connector on newly installed interface plate 4.2.7.5 DR removes P6A connector from old DBA II using connector tool 4.2.7.6 DR then attaches P6A connector onto J6B connector on newly installed interface plate 4.2.7.7 Repeat installation steps above for other diode box 4.2.7.8 GA moves DR back to tool box - GA Motion Software plots a path to move GA to EM Cargo Bay such that neither GA nor DR makes contact with HST or HRV. - GA Communications Software sends Move to Tools Command to GA to move GA and DR to Cargo Bay - GA Motion Software receives input from GA Joint Sensors to ensure that GA and DR do not come into contact with HST or HRV. 4.2.7.9 DR replaces its tool 4.2 Change-out for WFC3 4.2.15 GA and DR deployed (4.1) - SAME AS 4a.1 4.2.16 Install new ground strap temp stow fixture 4.2.16.1 Cargo bay with temp stow fixture opens 4.2.16.2 GA guides DR to bay - GA Motion Software plots a path to move GA to EM Cargo Bay such that neither GA nor DR makes contact with HST or HRV. - GA Communications Software sends Move to Bay Command to GA to move GA and DR to Cargo Bay - GA Motion Software receives input from GA Joint Sensors to ensure that GA and DR do not come into contact with HST or HRV.

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4.2.16.3 DR grabs temp stow fixture with 1 hand 4.2.16.4 DR releases stow fixture from bay attachments with other hand (7/16 hex interface) 4.2.16.5 DR removes temp stop fixture from cargo bay (linear retraction) 4.2.16.6 GA brings DR and temp stow fixture to handrail above WFC - GA Motion Software plots a path to move GA to WFC handrail such that neither GA nor DR makes contact with HST or HRV. - GA Communications Software sends Move to handrail Command to GA to move GA and DR to WFC handrail - GA Motion Software receives input from GA Joint Sensors to ensure that GA and DR do not come into contact with HST or HRV. 4.2.16.7 DR places temp stow fixture on handrail 4.2.16.8 DR attaches temp stow fixture to handrail 4.2.16.9 GA backs away from workspace - GA Motion Software plots a path to move GA to away from workspace such that neither GA nor DR makes contact with HST or HRV. - GA Communications Software sends Back away Command to GA to move GA away from workspace - GA Motion Software receives input from GA Joint Sensors to ensure that GA and DR do not come into contact with HST or HRV. 4.2.17 Install WF/PC II Interface Plate 4.2.17.1 GA moves DR back to cargo bay - GA Motion Software plots a path to move GA to EM Cargo Bay such that neither GA nor DR makes contact with HST or HRV. - GA Communications Software sends Move to Bay Command to GA to move GA and DR to Cargo Bay - GA Motion Software receives input from GA Joint Sensors to ensure that GA and DR do not come into contact with HST or HRV. 4.2.17.2 DR removes 3 guide studs securing WF/PC II interface plate in cargo bay 4.2.17.3 DR grabs WF/PC II interface plate with 1 arm 4.2.17.4 DR removes last guide stud securing WF/PC II interface plate 4.2.17.5 DR removes WF/PC II plate from bay 4.2.17.6 GA moves DR + plate to WF/PC II location - GA Motion Software plots a path to move GA to WF/PC II such that neither GA nor DR makes contact with HST or HRV. - GA Communications Software sends Move to WF/PC II Command to GA to move GA and DR to WF/PC II - GA Motion Software receives input from GA Joint Sensors to ensure that GA and DR do not come into contact with HST or HRV. 4.2.17.7 DR places WF/PC II plate in position with guide studs (using 1 arm) 4.2.17.8 DR attaches WF/PC II plate with 1 guide stud using other arm 4.2.17.9 DR releases WF/PC II plate from grip 4.2.17.10 DR secures WF/PC II plate in position with other 3 guide studs 4.2.17.11 GA backs DR away from workspace 4.2.18 Release blind mate connecter on WF/PC II 4.2.18.1 GA moves DR to blind mate connector - GA Motion Software plots a path to move GA to blind mate connector such that neither GA nor DR makes contact with HST or HRV. - GA Communications Software sends Move to BM Connector Command to GA to move GA and DR to blind mate connector - GA Motion Software receives input from GA Joint Sensors to ensure that GA and DR do not come into contact with HST or HRV. 4.2.18.2 DR releases blind mate connector 4.2.18.3 GA backs DR away from workspace

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4.2.19 Release ground strap and install on temp stowage fixture 4.2.19.1 GA moves DR to WF/PC II ground strap - GA Motion Software plots a path to move GA to ground strap such that neither GA nor DR makes contact with HST or HRV. - GA Communications Software sends Move to Ground Strap Command to GA to move GA and DR to WF/PC II ground strap - GA Motion Software receives input from GA Joint Sensors to ensure that GA and DR do not come into contact with HST or HRV. 4.2.19.2 DR grabs ground strap with 1 hand 4.2.19.3 DR releases ground strap from WF/PC II 4.2.19.4 DR pulls ground strap away from WF/PC II 4.2.19.5 GA + DR move ground strap to temp stow fixture - GA Motion Software plots a path to move GA to Temp Stow Fixture such that neither GA nor DR makes contact with HST or HRV. - GA Communications Software sends Move to Fixture Command to GA to move GA and DR to Temp Stow Fixture - GA Motion Software receives input from GA Joint Sensors to ensure that GA and DR do not come into contact with HST or HRV. 4.2.19.6 DR places ground strap in proper location on temp stow fixture with 1 arm 4.2.19.7 DR secures ground strap to temp stow fixture with other arm 4.2.19.8 GA + DR back away from workspace 4.2.20 Release A-Latch 4.2.20.1 GA moves DR to A-latch position on WF/PC II - GA Motion Software plots a path to move GA to WF/PC II A-Latch such that neither GA nor DR makes contact with HST or HRV. - GA Communications Software sends Move to A-Latch Command to GA to move GA and DR to ALatch - GA Motion Software receives input from GA Joint Sensors to ensure that GA and DR do not come into contact with HST or HRV. 4.2.20.2 DR grabs WF/PC II via WF/PC II interface plate with 1 arm 4.2.20.3 DR releases A-latch with other arm 4.2.21 Remove and stow WF/PC II 4.2.21.1 DR + GA linearly retract the WF/PC II from telescope 7.5 ft - GA Motion Software plots a path to move GA and DR, which is grasping WF/PC II linearly away from HST such that neither GA, DR nor WF/PC II makes contact with HST or HRV - GA Communications Software sends Remove Camera 1 Command to GA to move GA and DR away from Telescope - GA Motion Software receives input from DR Force/Torque Sensors (via EM Communications Subsystem) to ensure that camera is not lodged in telescope or constrained in its movement in any way 4.2.21.2 DR + GA move WF/PC II to the temp stow fixture - GA Motion Software plots a path to move GA to Temp Stow Fixture such that neither GA nor DR makes contact with HST or HRV. - GA Communications Software sends Move to Fixture Command to GA to move GA and DR to Temp Stow Fixture - GA Motion Software receives input from GA Joint Sensors to ensure that GA and DR do not come into contact with HST or HRV. 4.2.21.3 DR place WF/PC II on the temp stow fixture with 1 arm 4.2.21.4 DR attaches WF/PC II on the temp stow fixture with A-latch with other arm 4.2.21.5 Back away from workspace 4.2.22 Retrieve WFC3 and begin translation to HST 4.2.22.1 Move DR+ GA to cargo bay

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GA Motion Software plots a path to move GA to Cargo Bay such that neither GA nor DR makes contact with HST or HRV. - GA Communications Software sends Move to Bay Command to GA to move GA and DR to Cargo Bay - GA Motion Software receives input from GA Joint Sensors to ensure that GA and DR do not come into contact with HST or HRV. 4.2.22.2 Thermal contamination cover is retracted from WFC3 4.2.22.3 DR is moved to WFC3 ground strap 4.2.22.4 DR grabs ground strap with 1 arm and releases ground strap with the other 4.2.22.5 DR moves ground strap to cargo bay storage fixture with 1 arm and attaches it with the other 4.2.22.6 DR grabs WFC3 with 1 arm 4.2.22.7 DR releases A-latch with other arm 4.2.22.8 DR + GR linearly retract WFC3 7.5 ft from cargo bay of HRV - GA Motion Software plots a path to move GA and DR, which is grasping WFC3 linearly away from Cargo Bay such that neither GA, DR nor WFC3 makes contact with HST or HRV - GA Communications Software sends Remove Camera 2 Command to GA to move GA and DR away from Cargo Bay - GA Motion Software receives input from DR Force/Torque Sensors (via EM Communications Subsystem) to ensure that camera is not lodged in Cargo Bay or constrained in its movement in any way 4.2.22.9 DR_GA move WFC3 to WFC empty space - GA Motion Software plots a path to move GA to Camera Slot such that neither GA nor DR makes contact with HST or HRV. - GA Communications Software sends Move to Camera Slot Command to GA to move GA and DR to the vacant WFC slot in HST - GA Motion Software receives input from GA Joint Sensors to ensure that GA and DR do not come into contact with HST or HRV. 4.2.23 DR+GA move WFC3 into empty telescope space on HST (may require stabilization from 2nd arm) - GA Motion Software plots a path to move GA and DR, which is grasping WFC3 linearly towards HST such that neither GA, DR nor WFC makes adverse contact with HST or HRV - GA Communications Software sends Insert Camera Command to GA to move GA and DR into empty WFC slot - GA Motion Software receives input from DR Force/Torque Sensors (via EM Communications Subsystem) to ensure that camera is not lodged in telescope or constrained in its movement in any way 4.2.24 Once WFC3 is in place, DR drives A-latch with 1 arm 4.2.25 Re-install ground strap onto WFC3 4.2.25.1 DR grabs ground strap with 1 arm from temp stow fixture 4.2.25.2 DR places ground strap on WFC3 with 1 arm and secures it with the other 4.2.26 DR engages blind-mate mechanism 4.2.27 Detector vent valves (2) opened by solenoid values 4.2.28 Final stow of WF/PC II 4.2.28.1 DR+GA move to WF/PC II - GA Motion Software plots a path to move GA to WF/PC II such that neither GA nor DR makes contact with HST or HRV. - GA Communications Software sends Move to WF/PC II Command to GA to move GA and DR to WF/PC II - GA Motion Software receives input from GA Joint Sensors to ensure that GA and DR do not come into contact with HST or HRV. 4.2.28.2 DR grabs WF/PC II interface plate with 1 arm

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4.2.28.3 DR releases WF/PC II A-latch with other arm 4.2.28.4 DR + GA linearly retract WF/PC II - GA Motion Software plots a path to move GA and DR, which is grasping WF/PC II linearly away from Temp Stow Fixture such that neither GA, DR nor WF/PC II makes contact with HST or HRV - GA Communications Software sends Remove Camera 3 Command to GA to move GA and DR away from Temp Stow Fixture - GA Motion Software receives input from DR Force/Torque Sensors (via EM Communications Software) to ensure that camera is not lodged in Stow Fixture or constrained in its movement in any way 4.2.28.5 DR+ GA move WF/PC II to cargo bay WFC3 empty storage space - GA Motion Software plots a path to move GA to Cargo Bay such that neither GA nor DR makes contact with HST or HRV. - GA Communications Software sends Move to Bay Command to GA to move GA and DR to Cargo Bay - GA Motion Software receives input from GA Joint Sensors to ensure that GA and DR do not come into contact with HST or HRV. 4.2.28.6 DR secures WF/PC II via A-latch 4.3 Change-out for RSU 4.3.12 Move DR to conduit/ECU end GA Motion Software plots a path to move GA to ECU conduit such that neither GA nor DR makes contact with HST or HRV. - GA Communications Software sends Move to ECU Conduit Command to GA to move GA and DR to ECU Conduit - GA Motion Software receives input from GA Joint Sensors to ensure that GA and DR do not come into contact with HST or HRV. 4.3.13 DR grabs conduit/ECU end 4.3.14 DR moves it to circular connector interface on WFC3 4.3.15 DR attaches conduit/ECU end to circular connector interface on WFC3 4.3.16 DR opens bay 1 door 4.3.17 DR removes terminator plug on 486 (59) 4.3.18 DR places terminator plug in HRV cargo bay 4.3.19 DR grabs RSU 1553 bus end 4.3.20 DR moves it to bay 1 of HST 4.3.21 DR connects RSU 1553 bus end to 59 4.3.22 DR closes Bay 1 Stow DR

5.2

4.4.1 DR folds into stow configuration 4.4.2 GA moves directly over DR cargo bay 4.4.3 4.4.4 4.4.5 4.4.6

- Ground Control tele-robotically maneuveres GA with camera feeds as guide GC tele-robotically controls GA to lower DR into the DR cargo bay to within 0.16 accuracy. Stowing latches fix DR in stow position DR shuts down. GA EE detaches power/data plugs from DR EMGF - GC sends signal to trigger release action. - GA relays signal to plug motor in EE 4.4.7 GA EE releases DR EMGF and retracts 2m linearly 5. EM Jettison & Disposal 5.1 DR back in stow-away position inside isolated cargo bay - GA Motion Software plots a path to move GA to isolated DR cargo bay such that neither GA nor DR makes contact with HST or HRV.

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5.2

5.3 5.4 5.5

GA Communications Software sends Place DR in cargo bay Command to GA to move DR in to isolated cargo bay. - GA Motion Software adjusts GA camera to visually obtain the DR cargo bay. - GA Motion Software adjusts GA so DR aligns with DR cargo bay. - GA Motion Software moves GA to insert DR into cargo bay, adjusting the DR alignment based on visual input and force feedback. - GA Communication Software sends DR Replaced Signal so the EM will put in place the DR bindings. GA communication Software receives a DR Replaced Confirmed Signal. - GA Power Software turns off the DR power. - GA Motion Software releases the physical communication and power plug from the DR EMGF. GA Motion Software then releases the GA EE from the DR EMGF. GA Motion Software then linearly retracts GA 0.5m. - GA Communications Software sends DR Secure in Cargo Signal to Ground Control via EM GA folds back to original tie-down position on EM surface, reattaching the physical binds - GA Motion Software plots a path to move GA back to its original tie-down position on EM such that the GA will not make contact with the HST or HRV. - GA Motion Software moves back to its original tie-down position on EM surface. - GA Communication Software sends GA Replaced Signal to Ground Control via EM Ground control sends signal for EM to detach from DM EM performs evasive maneuvers to navigate away from HST EM performs de-orbit burns to reenter and burn up in atmosphere along with GA and DR

Hazards GA unexpectedly collides with an object (collision avoidance safety measure enabled) Video feeds from the cameras as well as other proximity sensor data shall be time-stamped and relayed to the GA processor where position, attitude, velocity and acceleration of GA relative to a nearby object can be interpreted Based on the data, software shall be able to determine whether GA is in a collision course with the object, and if so, estimate when the two objects will collide based on current position, velocity and acceleration data If the GA is within an estimated 10 seconds from collision, relay alert message to ground via communication subsystem, then slow down the approach GA (relative to object) to ensure a controlled approach If the GA is within an estimated 5 seconds from collision, relay warning message to ground via communication subsystem, then stop GA (relative to the object) to avoid collision If a collision does occur: o The ground control is alerted with emergency message about the collision o GA is maneuvered away from object o Software shall run a self-diagnostic, log errors and relay them to ground control o The GA cameras shall scan the area on both the GA and the collided object and relay the video feed to ground for assessment on physical damage Used in: 3.1a, 4a.6a, 4a.9a, 4.1.5.1a, 4.1.5.4a, 4.1.5.6a, 4.1.6.2a, 4.1.6.3a, 4.1.7.2a, 4.2.2.2a, 4.2.2.6a, 4.2.3.1a, 4.2.4.1a, 4.2.5.1a, 4.2.6.1a, 4.2.7.1a, 4.2.7.2a, 4.2.8.1a GA collides with an object while attempting capture (collision avoidance safety measure placed on stand-by) While other software algorithm is performing capture sequence (i.e. GA to HST or GA to DR), the collision avoidance sequence is running in the background without intruding to physically prevent the approach, however, the status messages will still be relayed to ground to inform them of a possible danger If the GA is within an estimated 10 seconds from collision, relay alert message to ground via communication subsystem but make no attempt to control the motion If the GA is within an estimated 5 seconds from collision, relay warning message to ground via communication subsystem but make no attempt to control the motion If a collision does occur, capture sequence shall have its own procedure to recover and retry capture. Hazard control software shall continue relaying information:

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o o o

alert ground control with emergency message about the collision Software shall run a self-diagnostic, log errors and relay them to ground control The GA cameras shall scan the area on both the GA and the collided object and relay the video feed to ground for assessment on physical damage

Used in 3.5a, 3.6a, 3.8a, 3.9a, 3.9b Communication problem (to ground control) EM communication subsystem shall relay information to and from GA and ground control When a message or data is relayed to ground, ground will automatically send a bounce-back signal to confirm that message was received If no such confirmation is received, software assumes the communication was unsuccessful and tries again, up to 3 attempts. If still unsuccessful, software reroutes the communication to a back up communication subsystem to reattempt communication. Used in 3.1b, 4a.2a, 4b.1a, 4b.5a Communication problem (cannot transfer data/messages with EM) GA software shall run a self-diagnostic and log errors, however, it cannot be immediately sent since the issue is data transfer is not possible Wait for ground control to diagnose the problem from the EM side and make modifications to EM software to hopefully restore communications with GA Once communication restored, send error logs to ground such that they can patch any problems in the software for the future Communication problem (cannot transfer data/messages with DR) GA software shall run a self-diagnostic and log errors Relay log to ground control If software problem, or an issue that can be rerouted in software, ground control will upload patch to fix the issue If a physical problem (i.e. connection not properly made), may have to uncouple and reinitiate capture sequence. Used in 4a.7a Unexpected failure of subsystem Software shall run a self-diagnostic to isolate the module(s) that are not operating correctly, as well as log the specific errors being generated The results of the diagnostic and error-log are relayed to ground control via communication system for evaluation In attempt to correct the error, ground control may: o Manually override to test certain individual parts or modules, make changes and try again to identify the problem o Switch to back-up systems to get around the problem o Upload patches to update the system software Used in 3.1c, 3.2a, 3.3a, 3.4a, 3.5b, 4a.1a, 4.1.1a Software malfunction the software shall perform a self-diagnostic, log the errors and transmit it to ground control through communications subsystem in EM the software shall be able to receive patch for software through the communications subsystem the software shall be able to update itself with the patch to fix any software bugs/add updates Used in: 2.1b

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D3: REFERENCES
[1] http://www.rcmarinecanada.com/scanrep.html [2] http://www.ri.cmu.edu/pubs/pub_246.html

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