National Aeronautics and Space Administration
Small Business Innovation Research & Technology Transfer 2004 Program Solicitations
TOPIC X4 Space Assembly, Maintenance, and Servicing
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X4.01 In-Space Assembly and Construction
X4.02 Self-Assembling Systems
X4.03 Inspection and Diagnostics
X4.04 Servicing, Maintenance, and Repair
The goal of the space assembly, maintenance and servicing topic is to enable a much more robust set of options for affordable implementation of ambitious new modular space exploration systems and missions, and means to drive down the cost of human exploration missions and campaigns beyond low Earth orbit. The objectives of this topic include:
1. Developing and validating technologies for the space assembly of large systems – including both science mission systems (e.g., observatories) and human operational systems;
2. Enabling autonomous and/or telepresence systems inspection;
3. Advancing remote or shared control of these capabilities in near-Earth and interplanetary space;
4. Developing and validating the capability to extend the life and reduce the costs if a new generation of space systems through repair, refueling, upgrades and re-use of components from one system to another;
5. Minimizing the effect of space system failures by enabling easy access for repair – thus reducing system-level functional redundancy (and associated costs);
6. Enabling a reduction in the total mass launched to orbit for given mission architectures;
7. Increasing the performance, autonomy, reliability and reduce the cost of performing Guidance, Navigation and Control (GN&C) for space missions; and
8. Establishing a foundation for profitable commercial development of space applications of these technologies in the mid- to long-term.
The space program can enrich society by directly enhancing the quality of education and providing many tangible benefits for Americans, as well as benefiting people the world over in their everyday lives. A goal of NASA is, therefore, to share the experience, the excitement of discovery, and the benefits of human space flight with all.
X4.01 In-Space Assembly and Construction
Lead Center: JSC
Participating Center(s): ARC
This subtopic seeks innovative technologies that improve robotic joints, actuators, end-effectors, mobility devices and mechanisms for on-orbit aid to human explorers. Proposals should address how to resolve issues associated with:
- Material and component compatibility within the intended operating environment
- Reduction in mass without compromising material strength
- Design modularity to accommodate multiple tasks
- Design flexibility to assure extended useful lifetime through mechanism upgrades
- Design simplicity to facilitate easy repair
Specific areas of interest include the following:
1. Technologies or systems that provide a reduction to the weight and or volume of robotic systems such as:
- Reduced scale (<50 in3) high power-to-weight ratio (actuator output force >25:1) gripping actuators.
- Miniaturized (<0.1 in3) actuator control and drive electronics.
- Miniaturized (<0.025 in3) sensing systems for manipulator position, rate, acceleration, force, and torque.
2. Robotic systems that can grapple, manipulate, and operate existing Extra-Vehicular Activity (EVA) tools while maintaining a small, human-sized form factor.
3. Compact (<4 ft3), low power (<1 kW peak draw and < 500 W average continuous draw) devices for site setup and preparation for human presence on orbit. Examples include site clearing and setup devices, equipment deployment and retrieval devices, and the actuation components for these devices.
Proposals are solicited for innovative, integrated, sensor concepts that serve to maximize functionality, minimize weight, size, cost and failure probability, or increase mission performance or versatility of Extra-Vehicular Robots (EVR). Categories of EVR include, but are not limited to, free-flyers for external inspection of manned spacecraft and humanoid robots for external servicing of manned spacecraft.
A free-flying, remotely controlled imaging platform capable of transmitting images to its operator could provide images on demand of the exterior of the Space Shuttle, the International Space Station (ISS) or a future Space Solar Power (SSP) Satellite to inspect for damage, plan or supervise repair work, etc. Technology needs include:
- Model-based landmark navigation to allow a free-flying camera platform to find its way around the outside of the ISS without requiring expensive external beacons, including the ability to update the model (space station for example) as it changes.
- Machine vision techniques, including construction of image mosaics, for detection of unspecified changes in objects being inspected under diverse or changing lighting or viewing conditions.
- Sensing to minimize the risk of collision between the imaging vehicle and target vehicles, such as:
- Small (<0.2 in3 volume), lower power (<0.05 W), range/range-rate sensor
- Small (<0.2 in3 volume), lower power (<0.1 W) "ranging" sensor that produces a depth map of the scene
- System on a Chip (SOC) imager that captures infrared (IR) images of a scene
A humanoid robot designed to have the dexterity of a space-suited astronaut would be capable of operating tools and performing repairs on a manned spacecraft that was originally designed for human operation. Specific technology needs include:
- Miniature (<0.05 in2 sensor area) robust sensor material for measuring position or strain.
- Sensors with integrated multiplexing to reduce wire count.
- Sensor material must be space qualifiable for temperature extremes and outgassing.
An effective human/robotic interface enables humans and computers to seamlessly control anthropomorphic robotic systems. Proposals are sought that improve the robotic teleoperator's efficiency through advanced display systems, haptic feedback systems and telepresence control interfaces. Specific technology requirements include the following:
- Unencumbering, lightweight (<5 lbs) teleoperator-worn tactile and force feedback devices that provide operator awareness of manipulator and payload inertia, gripping force, and forces and moments due to the robot's contact with external objects.
- Innovative miniaturized display hardware for use with Helmet Mounted Display (HMD) systems that project data in a Heads Up Display (HUD) format. Emphasis is placed on compact (<0.3 in3 volume), low mass (<2 oz) hardware that can be used with HMD displays and efficiently display data (graphical and alphanumeric) without detracting from the HMD displayed video.
- Virtual reality interfaces that make it practical for an Intra-Vehicular Activity (IVA) astronaut or a suited EVA astronaut to operate on-orbit free-flyer camera platforms and planetary robotic camera platforms.
- Innovative systems that permit control of a robotic system through a combination of gesture and voice commands. Innovative concepts include machine vision, artificial intelligence based systems (with provision for crew oversight), as well as other nonvision forms of sensing and perception that provide command input to the robot.
- Miniaturized High Definition Television (HDTV) video cameras for use in capture of live video. Cameras should not exceed 2 inches in width and 2 inches in height with respect to the optical plane and should not exceed 4 inches in depth along the optical axis. An integrated zoom lens and an external sync capability is highly desirable. In addition, the camera shutter should operate on a global basis, i.e., all pixels on the imager should be exposed simultaneously instead of exposing one row of pixels at a time.
- A Helmet Mounted Display (HMD) that uses the HDTV format. Emphasis is placed on minimizing the weight (<3 lbs) of the HMD. Wide horizontal field of view (>150°) and high resolution (<2 arcminutes per pixel) are key objectives of this technology.
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X4.02 Self-Assembling Systems
Lead Center: JSC
Participating Center(s): ARC, MSFC
In support of future robotic and human missions, the need for additional automation in rendezvous and docking has been identified. This subtopic addresses hardware and software technologies necessary to develop a robust automated guidance, navigation, and control (GN&C) capability bringing together to mate two vehicles from initially large distances (> 1000 km). The "target" vehicle may be orbiting the planet or Moon for several years prior to the rendezvous. The "chaser" vehicle may begin the rendezvous after launch from the planet or Moon's surface. Because of intended use for future human missions, the rendezvous and docking capability must be low risk ensuring a very high level of mission success. The proposed system should be modular and adaptable to smaller robotic missions in order to validate the technology and spread the investment and experience base.
For the purposes of this solicitation, the target vehicle is in the vicinity of the Moon, either orbiting the Moon at low altitudes or at the Earth–Moon L1 libration point. The chaser can be launched from the Earth or the Moon's surface. The proposed system may include active components on the target vehicle if a high level of mission success can be ensured over long timeframes. Preferred solutions support rendezvous operations with nonfunctioning target spacecraft at least in a contingency sense.
Innovations are currently sought to solve the following specific technology challenges (single sensor navigation solutions to address both items below are preferred):
- Definition and development of a small lightweight relative navigation system addressing spacecraft-to-spacecraft ranges of 100 km to less than 100 m. This system should provide precision relative-state position and velocity data needed for trajectory control and be capable of supporting trajectory operations for various rendezvous and proximity operations mission profiles, including circumnavigation of the target, and final separation and departure operations.
- Definition and development of a small, lightweight relative navigation system providing position and velocity trajectory control and relative attitude control during the final 100 m of the approach through mating.
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X4.03 Inspection and Diagnostics
Lead Center: LaRC
Participating Center(s): ARC, JSC, KSC
Innovative and commercially viable concepts are being sought for the development of resilient space qualified non-destructive evaluation (NDE) and health-monitoring technologies for in-flight and on-orbit inspection and maintenance of space transportation systems. Emphasis is focused on highly miniaturized, lightweight, and compact systems that deliver accurate assessment of structural integrity. NDE systems that provide the greatest improvement in structural defect detection with minimum weight penalty will be given the highest priority. Structural applications to be considered for NDE and health monitoring development include but are not limited to:
- High stress and hostile aerodynamic, thermal, and chemical service environments projected for complex structural space vehicle systems; and
- Autonomous, non-contacting, remote, rapid, and less geometry-sensitive technologies that reduce weight and acquisition costs or improve system sensitivity, stability, and operational costs.
Evaluation sciences include ultrasonics, laser ultrasonics, optics and fiber optics, shearography, video optics and metrology, thermography, electromagnetics, acoustic emission, and x-rays. Innovative and novel evaluation approaches are sought for the following material and structural systems:
- Adhesives, sealants, bearings, coatings, glasses, alloys, laminates, monolithics, material blends, wire insulating materials, and weldments;
- Thermal protection systems;
- Complex composite and hybrid structural systems;
- Low density and high temperature materials; and
- Aging wiring.
Proposals should address the following performance metrics as appropriate:
- Characterization of material properties;
- Assessment of effects of defects in materials and structures;
- Evaluation of mass-loss in materials;
- Detection of cracks, porosity, foreign material, inclusions, corrosion, and disbands;
- Detection of cracks under bolts;
- Real-time and in situ monitoring, reporting, and damage characterization for structural durability and life prediction;
- Repair certification;
- Environmental sensing;
- Planetary entry aeroshell validation;
- Micrometeor impact damage assessment;
- Electronic system and wiring integrity assessment, wire insulation integrity and condition (useful life) and arc location for failed insulation;
- Characterization of load environment on a variety of structural materials and geometries including thermal protection systems and bonded configurations;
- Identification of loads exceeding design;
- Monitoring loads for fatigue and preventing overloads;
- Suppression of acoustic loads;
- Early detection of damage; and
- In situ monitoring and control of materials processing.
Measurement and analysis innovations include, but are not limited to:
- Advancements in integrated multifunctional sensor systems;
- Autonomous inspection approaches;
- Distributed and embedded sensors;
- Roaming inspectors;
- Shape adaptive sensors;
- Concepts in computational models for signal processing and data interpretation to establish quantitative characterization and event determination;
- Advanced techniques for management and analysis of digital NDE data for health assessment and lifetime prediction;
- Biomimetic, and nanoscale sensing approaches for structural health monitoring that meet size and weight limitations for long duration space flight.
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X4.04 Servicing, Maintenance, and Repair
Lead Center: KSC
The purpose and scope of the subtopic is to develop technologies and concepts for servicing, maintenance, and repair of space exploration systems. These systems include crew living quarters, laboratories, airlocks, ground transportation systems, and space transportation systems. The related support systems include environmental control systems, waste collection and processing systems, food storage and preparation systems, power systems, pneumatic systems, fluids systems, computer systems, communications systems, instrumentation systems, various structures and mechanisms, and other tools and equipment. Commodities may include gaseous and liquid nitrogen, oxygen, hydrogen, methane, carbon dioxide, and water. Operational environments include micro- and partial-gravity, possible corrosive reactivity, thermal extremes, possible low visibility, high potential for static discharge, possible cosmic radiation, and extensive permeation of dust-like materials. Requirements include safe operation, high reliability, ease of use, multiple uses, low-system volume, and low power. Operational concepts include limited direction from Earth-based mission control teams, minimized crew times in performance of these activities, optimal system autonomy, and optimal system readiness. In addition, all failure scenarios are expected to be designed to be “fail operational–fail safe.” NASA seeks highly innovative technologies and concepts to address efficient, accurate and cost-effective servicing, maintenance, and repair of space exploration systems. Specific technical areas include the following.
Upgradeable and Reconfigurable Systems Concepts
Support systems for the space exploration systems need to be developed which provide for a “Zero Outage” environment. Support systems must have the capability to be upgradeable through incremental component level upgrades. Support systems must also have the capability to be reconfigurable through the use of subsystems, components and connections that are multi-use, multi-commodity, and used in multiple environments. These reconfigurations must also have the capability of being performed autonomously to restore critical functionality. Expected products include concept papers, and subsystem or component level prototype demonstrations.
Standards, Interfaces, and Architectures
Standards, Interfaces, and Architectures need to be developed that support common and abstract definitions of both physical and behavioral characteristics, as well as shield internal technology-specific details from external system elements. The goal is to develop truly modular components that provide “Plug and Play” functionality between spacecraft and spaceport, between spacecraft elements, and between spacecraft and in-space or surface elements. Expected products include concept papers, and subsystem or component level prototype demonstrations.
Modular Orbital Replacement Units
It is expected that certain maintenance and repair actions will be performed by astronauts during Extra-Vehicular Activities (EVA). Astronauts will remove, replace, and retest units having characteristics of multiple functionality, integrated intelligence, adaptive interfaces, and interconnections. In addition, development of the associated equipment, tools and procedures, will be required to ensure a successful recovery from a system-level failure. Expected products include concept papers and prototype demonstrations.
Modular Component Replacement Units
It is expected that certain maintenance and repair actions will be performed by astronauts in a laboratory setting. Astronauts will remove, replace, and retest components contained within higher level units. Characteristics to be addressed include component mating surface preparations such as cleaning and polishing, electrical component contact soldering or annealing, and multiple functionality of the spare components. In addition, development of the associated equipment, tools, and procedures will be required to ensure a successful recovery from a component level failure. Expected products include concept papers and component level prototype demonstrations.
Propulsion System Refurbishment and Repair
The goal is to develop propulsion system component level technologies that support in-space modular replacement, commodity servicing, and in-place diagnostic and health determination. Capabilities need to be developed for remote and NDE inspection and testing of system components. The capability to repair or replace fluid lines either by human EVA or robotically operated tools will need to be developed. In addition, development of capabilities to safely isolate, inert and disengage fluid, mechanical and electrical interconnects will need to be developed. Expected products include concept papers and subsystem or component level prototype demonstrations.
Refueling and Fluids Resupply Support Systems
Multiple elements will have interfaces that will require the transfer of commodities between them to allow for integrated systems operations. These commodities will typically be electrical power, data, communication, pneumatics, coolant fluids, cryogenic fuel and oxidizer, and other systems related commodities as required. Umbilicals are mechanisms that enable these connections between multiple elements and can be manually operated or autonomous. Depending on the specific operation, both manual and automated umbilicals will be required to enable deployment and operation of space-based equipment, facilities and habitation modules. It is expected that these umbilicals will have leak detection capability, remote sensing, use self-healing characteristics and low-maintenance sealing technologies. In addition, the systems being serviced must have advanced volume-gauging systems. These servicing systems must also demonstrate safe and secure operation. Expected products include concept papers and subsystem or component level prototype demonstrations.
Structural Materials-Level Repair Systems
Develop in-space capabilities and technologies for material repair both via human EVA and robotically operated disassembly, welding, bonding, insulation application and reassembly. It is also highly desirable to develop technologies for polymeric and composite materials that mimic the self-healing repair processes of biological systems. Applications for self-healing processes of inanimate materials can be found in areas where failures could result in catastrophic consequences. Examples include: failure of structural members, failure of electrical wire insulation materials or failure of polymeric membranes used in critical life support systems for separations of gaseous and liquid commodities. Expected products include: concept papers and laboratory demonstrations.
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