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Final Report - [Almost] Daily Photos

1. mm IR Emitter IR Recievers a Lower Arm Upper Arm wi 24V Breaker 4 BUS I ADS EMI Filter 24V Breaker Controller Limit Voltage Regulator EMI t ilter Switch Voltage Regulator ve Limit I i Switch fx T T D gt Joint Shaft Motor Shaft Motor Micro i Encoder Encoder Motor Power Controller i Amplifier Winding 1 and Switching e e 274 Switching Gearbox Motor indi i powa mm a Winding 2 Motor Power i Amplifier Joint Shaft _ MotorShaft and Switching H Encoder Encoder Motor Micro 3 Controller i ve Limit Switch He eae i H ve Limit He ep Switch Voltage Regulator Voltage Regulator 1 06 Filter EMI Filter 1 12V Breaker d 12V Breaker T Controller i IR Emitter IR Recievers T l ral BUS P9A 12V e 4 lt eus 048 1553 127 Appendix 7 2 3 EFBD 2 Thermal Control System Bus D4A 1553 Bus D4A 1553 Temperature AID Controller Thermocouple Voltage regulator Kapton Heater
2. eee eee BS PRA 24V gt Bus D1A 1553 gt IR Emitter IR Recievers IR Emitter IR Recievers pj Tool I End Eftector vi y 24V Breaker 4 Reset BUS m ADE EMI Filter ZAV Breaker 4 Controller 4 Voltage Regulator EMI i ilter Voltage Regulator 1 1 h AN gt j A gt Motor Micro AER AN P px Controller ve Limit Van Y Switch Motor Power 4 i Amplifier i Winding 11 4 and Switching Gearbox Motor Winding 2 AR Moin Power a Amplifier i and Switching lt i ve Limit i Switch jd Limit i yen Motor Micro g Controller e poche 1 Voltage Regulator Voltage Regulator E AD C EMI Filter EMI Filter 1 12V Breaker 4 12V i Controller 1 H t IR Emitter IR Recievers IR Emitter IR Recievers T 25 018 1553 132 MESA sajpung BUS 5 1553 BUS D5A 1553 MESS sajpung D5B Master Bus Controller V3 Master Bus Controller V4 Master Bus Controller accio ec CPU ision Backup Vi ision CPU Vi 133 Main CPU D5A Master Bus Controlle
3. 14 5 117 Operational POUCIOS aea Ea o E Eaa E EE 14 3 1 2 Oper tional Constraints iiit pe 14 5 1 3 Operational Environment sorsien eese rie vies rne E E AE EREA E E 14 2 2 IPUNCTIONAL a neto Er iD 15 3 2 Operations Timeline i c t dep Ego Lene bodies td 15 2 3 DR GA INTERACTION Pest iu ci 16 531 DR grappling and activation saei ee tee en op e ete Race Pede 16 5 3 2 repositioning during 17 23 43 DR 7 GA emergency stop i ee eerte ote ei eU ee ues sede Up SUE Slee a dean 17 5 34 DR Stow and un grappling edes rta te oed 17 54 OPERATING MODES See RIP YE E Ee EHI Tee i E od testo e 17 259 18 5 9 1 Operational Scendti S esigia etre tee eei Y EEEE E E E E sep a 18 5 5 2 Failure Modes and Effects 19 5 6 GROUND CONTROE ARCHITEC TURE s
4. oS SENE E pe 169 1 IJCDNOMENCLATURE EUN FO PRU RE eoe PERDRE PU 170 2 ICD MECHANICAL INTEREA viicisssscsvoccasisostsosecvstiesssusstsunqwertestsentsevenvedsebesssstensavest oaseodsesetvs 171 2 1 STRUCTURE mh i ite endete e leen ioc comis od 171 2 2 DR STOWCONEIGUR ATION teet duds 171 23 CAPTURE ENVELOPE str e oe td eee ce tecta tec iai tte P 172 24 rmm 172 2 5 eds EE 172 ICD ELECTRICAL INTEREFA C Eis si ccscscccdecesssccesssecccdocsetoossssecsccccsescossssaceceesdedvovsssasecessvesdenssseseoee 173 ICD SOFTWARE INTERFACE fc siscccccsccccsossiocsecsscoseosiesesocossseseccsesessvesdscceesiesesecessseseccsosessvesdecseede 174 4 1 COORDINATE SYSTEMS RW asa qe aee ode diei 174 4 2 COMMUNICATIONS 5 ere eve ewes ga vede adve arte te Nee evi te va et e eoa 174 4 2 1 Emergency Stop Command usen eR e eat ee e mes 174 4 2 2 From Ground Control to DR IGA 1cccccccccccccssssssessccccccsscsscsscccccesssesessecescasssesecsescsccesscssescccsesesaessscess 174 4 2 3 From DR GA To Ground Control ccccccccccccscssescececccccccussscseeccccccussseceececcscussscseecccessususeccececessusuaeccesecs 174 4 2 4 DR Ground Control to GA Ground Control eese eee eene 175 4 2 5 GA Ground C
5. uj 8 Voltage regulator Temperature AID Sensor Converter Thermocouple Controller 4 i J 2 Bus D4B 1553 BUS P10A 30V E T BUS P10B 30V 128 Appendix 7 2 4 EFBD 3 LCS EU Control Unit E T sci es LCS ee gt gt t 1 1 1 1 ca E 1 1 1 run Q l Do Do 25 3 9 i 12 12 Po oF ol dj 5 mE o 2 i z ul EE L 1 t 5 i 5 E E 9 9 1 al i a 1 Y Y o 1 1 5 1 gt gt 5 5 i mt ng 1 i 8 8 M pre 1 1 129 Appendix 7 2 5 EFBD 4 Tool Caddy EU DR Body Contact switch Contact switch Contact switch Contact switch Contact switch Contact switch Contact switch Contact switch Contact switch Contact switch Contact switch Contact switch Contact switch
6. eese eene nennen 147 Appendix 8 3 3 Tool Manipulator Material Selection eese tentent een 146 Appendix 8 3 4 General Manipulator Arm Calculations esee rennen 149 Appendix 8 3 5 General Manipulator Joints Calculations eese eene 150 Appendix 8 3 6 General Manipulator Material Selection Calculations eese 151 Appendix 8 3 7 Motor and Gearbox Calculations eese 152 Appendix 8 3 8 Motor Sample CalculationsGA Interface eee eene nennen rennen 153 Appendix 6 3 0 GA Interface ier Ee He e ERE RE ee 154 APPENDIX 8 4 MODAL ANALYSIS isses enne nennen nnne tnt nennen nete nennt retener enne 154 Case 1 Arm with 10001 Payload 155 Case 2 Arm with no Payload on teen 156 APPENDIX 8 5 THERMAL CONTROL SUBSYSTEM cscsssssssscsesseseseescecsessesesesececsesssesesececsenssassesecessenasaesenecessenes 158 APPENDIX 8 6 END EFFECTOR 1 20 2 1 ene een enn nennen eren nennen nennen 161 APPENDIX 8 7 DETAILED MASS BUDGET T ricuni oserei gei Easo ieSe ENES EEEE EE E rennen nennen nennen 165 APPENDIX 9 5 167 APPENDIX 10 INTERFACE CONTROL DOCUMENT esee esee enean natn aeta sts sosta sins en 168 ICD TABLE OF CONTENTS
7. 183 6 4 Load Calculations Loads on the GA DR fixture during extreme cases Stopping 100016 Iw FOS _ Equivalent Load on fix Linear Force case Distance from force to centre of fixture Torque case Distance from torque centre to centre fixture Applying a 50 ftlb Torque Torque Distance from torque centre to centre fixture 6 5 Cable Mass Calculations 32 wire bundle through the GA density Cu 8960 kg m 3 Wires current required at circuit interface length m wire gage 1 92 0 87 15 225 7 Connectors mass per number of connector mass connectors kg kg 1000026 02 Total mass of cables through 3 39 kg 184 6 6 Electrical Interface Requirements 6 6 1 Power Interface Number needed for requirement ARM 1 TCS 115V Primary ARM 1 TCS 115V Backup 2 includes return line 2 includes return line ARM 1 115V Backup ARM 1 115V Primary 2 includes return line 2 includes return line ARM 1 24V Primary 1 2 includes return line ARM 1 24V Backupl 2 includes return line ARM 1 24V Primary 2 2 includes return line ARM 1 24V Backup2 2 includes return line LCS 24V Primary 2 includes return line ARM 2 TCS 115V Primary 2 includes return line ARM 2 TCS 115V Backup 2 includes return line ARM 2 115V Primary 2 includes return line ARM 2 115V Backup 2 inclu
8. and which tools Joint postion torque at EE are present EM Communication thermal Thermal Sensors GA Communication Emergency proximity Sto Collision information p avoidance Sensors fault data and corrective actions NM Electrical Fault Recovery System Data Inter processor Ground communication Communication Video Lighting V System 2 on off lighting ys Video Camera 4 video data motor control and data LCS data LCS Pan Tilt tracking and scan Motor controllers 2 LCS System 2 Figure 6 5 Level 0 Software Architecture 6 4 3 Level 1 Breakdown Our dual architecture can be broken down further into software nodes contained within each of the main control and the vision system Please see Figures 6 6 and 6 7 6 4 3 1 Level 1 Main DR Command The main command module will handle all non vision operations of the DR The main command modules will individually process these tasks while the MCOS Main Command Operating System will handle the computer system resources and the lower level tasks The main command module will contain the following software modules Redundancy Control This module will only be active if there has been a failure detected in the DR s power or data bus system The redundancy control system will take corrective action
9. mer Pen Fixture Tool Tool Clip Tools Thermal Control System SE ESSE End Effe weder TOS Joint Mechanis Solar Heat e Structural Mechanisms Mechanisms Force Torque Radiative Heat Loss el DOF Focal dn TOS Sensor dont Ray mm Sensor Pointing GRE i Sensor Ejection Module 9 Mechanism Sere Encoder tPSTCS 21 12009 Hee eme Te Docking Latches le Se seen and CHDH TCS GA Im Actuators EPS cM 8 UD gis DR HIE System Ground Control E LEGEND Blocks External to but interfacing with the RSS Blocks Representing Subsystems Box Components Large Extemal Environmental Arrows Interfaces to the RSS Internal Interfaces between Subsystems of the RSS 2 d ie Internal Interfaces between A Subsystem Components of the RSS Gens Blocks Representing Subsystem 53 91 Appendix 4 Failure Mode Effects Analysis Potential Failure Mode Failure Effects mo In what ways What is the canthe Key impact on the Input go customer wrong requirements What is the Action Category How often How severe Potential Causes What causes the Key Input to What are the control strategies that w
10. Contact switch 1553 eee mee nnn ne lt Tool Cady Microcontroller Bus Controller Tool Cady Microcontroller ig ESSI S 42222221 Voltage E REN Regulator i 220777771 Voltage Regulator 3 4 y us Controller Breaker BUS P6B 28V BUS P6A 28V 4 130 Appendix 7 2 6 EFBD 5 Tool Gripper MEU 05 QV CLS See Se gt Bus 1553 E Emitter IR Recievers IR Emitter IR Recievers vi 24V Breaker 4 BUS ADC ADC Fier 24V Breaker controller T 2 Voltage Regulator EMI t ilter
11. EEE EO ETERN 3 3 3 p AEiU d 3 3 4 MISSION PROFILE EE 4 AE SEEN LX E 4 34 2 Misston E 4 DEXTEROUS ROBOT 1 seta stato se tastes sonata 6 4 1 EVEL REQUIREMENTS ierit irc tier ERE ONT e ERE Ee estie NOE agies aiana E aE eaa ia 6 4 1 1 Functional Requirements esee 7 41 2 Performance Requitemelisesauuie secre rette ee tet etr hee ep Ia Og I ee RHOD 7 4 2 SYSTEM ARCHITECTURE Pie Seren PIE 8 B21 E eS IHE amp 42 2 System Block 10 4 3 IDR CHARACTERISTICS OE 11 aE 11 492 Power Budget E 13 4 3 3 Mass 13 44 SYSTEM CONCLUSION M AE EER EEKE 13 OPERATIONS 14 5 1 OPERATIONAL OVERVIEW 2222
12. has b d d erate cPCI em target The SCS750A has been designed to operate system target Ultimate Upgradeability ing high performance computing and memory for the most demand Software Selectable Power Consumption ing space applications Its design decisions have been driven by a from 7 25 watts guarantee of the highest reliability and performance Maxwell has Standard Development Platform Compatible developed a comprehensive radiation mitigation strategy to provide with IBM s PowerPC750 total dose hardness latchup immunity and upset error mitigation for the SCS750A Maxwell s SCS750A has become the benchmark of which all future space processor boards will be measured NE TECHNOLOGIES There is a trend to perform data management and manipulation on Doc SCS750AP Prototype Layout SCS750A As shown uses commercial components Flight board conduction cooled with space qualified components PMC Slots for Engineering Development System Controller PCI PCI Bridge Reed Solomon FPGA w TMR and EDAC Protected Reed Solomon Logic SDRAM 2 Serial Ports iy onl x 6 A d Three 3 RS 232 Ya gy pis TMR Protected PPC750FX Push Button Switches amp LEDs for Error Injection and Board Reset EDAC Protected Clock Distribution EEPROM SCS750AP For hardware amp software development amp integration 2 UARTs RS 232 vs 1 UART LVDS on AD AE amp AF Models
13. 1 67 rad sec and 6 1 16 105 11 3 Root Locus Plot 22 49559 41 84085 83 2817 106 11 4 Bode Plot Figure No 1 107 11 5 Step Input Response Step Response Amplitude Y 2 3 4 Time sec 11 6 Correspondence with Dr Chad English PhD NepTec Hello Dr English Thanks for your reply it really helped to clarify some misconceptions had about the LCS SVS and vision systems in general As my space systems course has been progressing we have finally returned to vision systems as a final topic and think perhaps know enough now to ask some better questions Before doing that though thought might give you a bit of background about our project so that you might understand what is motivating my interest in NepTec s LCS Our fourth year space systems project is to design a robotic servicing system that will repair replace hardware on the Hubble Space Telescope and provide it with a controlled de orbit capability for it future disposal All this of course has to be done without any immediate human presence and requires the use of an advanced vision system this 108 is where your LCS sensor comes in My team is responsible specifically for designing a dexterous robot which will perfrom the close range serviicing operations So here are some questions I ve thought of 1 I ve selected the LCS because it can operate any lighting condition Immu
14. 39095K67 15 10 328 to 700 d 39095K68 16 20 T 328 to 700 F 39095K69 17 30 328 to 700 39095K243 19 50 4 Type 316 SS Probes dia with 3 ft Fiberglass Cable J 32 to 1400 F 12 0 5 900 F 39095K51 24 20 1 32 to 1400 F 18 0 5 900 F 39095K52 26 40 432 to 41400 F 24 900 39095 53 26 40 4 Type 316 SS Probes v2 dia J with 3 ft DM Cable Cont 32 to 41600 F 12 0 5 900 F 39095K54 24 20 432 to 41600 F 18 39095K55 26 40 K 432 to 1600 F 24 39095K56 26 40 328 to 700 F 12 39095K57 24 20 328 to 700 F 18 39095K58 26 40 328 to 700 F 24 0 5 39095K59 26 40 5 Type 316 SS Probes Car dia w J 32 to 1400 F 0 3 221 F 39095K95 57 51 432 to 1600 221 F 39095K96 57 51 328 to 700 F 221 F 39095K97 57 51 6 316 SS Probe 6 dia with 3 ft Type 302 SS Cable J 322 to 1400 F 24 1 F 39095K11 105 84 K 432 to 1600 F 24 400 F 39095K12 105 84 7 Bare Tip Probes Ge dia with 3 ft PTFE Cable J 40 to 400 F YJ 400 F 6441T671 20 82 K 40 to 400 F 400 F 6441T672 20 82 T 40 to 400 F
15. ugpiu aq 0 sue euis aa 04 YH 103 BUNEA Burgiou og 10 7 00 puno4D s u ag pueuiulo SJO 2y UMBIP YIM 3q 01 aA WO 2819 j043407 ya 701 aseajag 4035 1047107 1 4521 puas YT Awouoyny ainjdeo 34894 95 uuogiad 04 Yq 84315 j047 07 punoar Jo sjo e1 Urna yur usr qe1sq 1043507 0 SE UOISSIIN dn mod 01 yqq 2081 punon sr jeu WO URIS 7047407 puno4p anjdeo 03 YO 103 Sure oq 047407 Seq jo Buruado 7044407 155 TUI 1047400 punon Mob 0 101 di Mission Task Command Flow DR service operation Events 102 Appendix 6 Controls 11 1 Dynamic Model We model the DC motor armature to have resistance and negligible inductance The speed of the motor generates a back emf voltage The equations governing the motor with torque constant K is e i R V 0 where is the voltage supplied at the armature Ra is the armature resistance i is
16. 2 9262T56 325 to 41500 6 9262T58 325 to 600 F 2 9262T36 325 to 600 6 9262T38 J 325 to 1500 9262T66 K K K 2325 to 41500 9262 68 CARR ENGEL Worm Gearheads 1 133 oz in Motor and Gearhead combinations G2 6 fits motor series GNM3150 G3 1 fits motor series GNM5440 Series 62 68 637 G2 6 amp G3 1 See beginning of the PMDC Gearhead Section for Ordering Information G2 6 G3 1 Housing material metal metal Backlash at no load lt 1 5 lt 1 5 Shaft load max radial Ibs 33 8 45 axial 165 13 5 18 Series G2 6 with Motor Series GNM 3150 length output torque reduction ratio weight with continuous intermittent direction efficiency without motor operation operation of rotation motor GNM 3150 M max max max max reversible Kg Ibs mm in Nm oz in Nm oz in 4 8 1 0 45 0 99 179 7 05 0 7 99 1 7 991 3 82 os 0 45 0 99 179 7 05 1 3 184 1 7 991 3 80 12 1 0 45 0 99 179 7 05 1 6 226 6 7 991 3 80 14 5 1 0 45 0 99 179 7 05 2 0 283 2 7 991 3 78 20 1 0 45 0 99 179 7 05 2 4 339 9 8 1 132 9 70 25 1 0 45 0 99 179 7 05 22 7 382 4 8 1 132 9 66 30 1 0 45 0 99 179 7 05 3 0 424 8 7 991 3 67 36 1 0 45 0 99 179 7 05 2 5 354 0 5 708 1 63 Series G3 1 with Motor Series GNM 5440 engt output torque reduction ratio weight with contin
17. 400 F 6441T673 20 82 8 Bare Tip Probes gs dia with 15 ft PTFE Cable J 40 to 400 F 2 7 400 F 6441T821 42 34 K 40 to 400 F 400 F 6441T822 42 34 T 40 to 400 F 400 F 6441T823 42 34 9 Bare Tip Probes Ehe dia with 4 ft Fiberglass Cable J 40 to 4896 F 9 896 F 6441T941 27 05 K 40 to 4896 F ve 9 896 F 6441T942 27 05 T 40 to 4896 18 9 896 F 6441T943 27 05 Penetration Immersion Thermocouple Probes with Flat Pin Mini Connector Wd 125 Wd Flat Pin Mini Connector _ mE SS 11 12 15 C2 16 18 S 19 20 S Designed for penetrating into soft materials and for immersing into liquids These thermocouple probes are made of Type 304 stainless steel All have male flat pin mini connectors Note Response times Max Probe Type Probe Response Cable Temp Range Lg Time sec Temp Each listed below are approximate Styles 10 12 amp 14 Have a self retracting coiled cable Styles 16 18 Have a green PFA coated stem Max Probe Type Probe Response Cable Temp Range Lg Time sec Temp Each 10 Straight Tip Probes dia with 4 ft Coiled PVC Cable J 40 to 500 40 176 39105 76 547 85 K 40 to 500 176 F 39105K72
18. 47 85 T 40 to 500 442 176 39105 91 47 85 11 Reduced Tip Probes pe dia with 4 ft Coiled PVC Cable J 40 to 500 F 176 F 39105K651 54 78 K 40 to 500 F 176 F 39105K652 54 78 T 40 to 500 176 39105 653 54 78 12 Reduced Round Probes dia w 4 ft Coiled PVC Cable J 40 to 932 F 176 39105 411 106 93 K 40 to 932 F 176 39105 412 106 93 T 40 to 662 12 176 F 39105K423 106 93 13 Pointed Probes dia wit Handle and 5 ft Type 304 SS Cable J 7310 to 41400 F 10 900 F 39105K211 98 78 2418 to 1652 F 10 900 F 39105K212 98 78 418 0 750 F 10 10 700 F 39105K313 98 78 14 Heavy Duty Pointed Tip Probes 516 dia with T Handle and 6 ft Coiled Polyurethane Cable 166 to 4400 F 36 220 F 9261T36 187 04 166 to 400 F 48 220 F 9261T48 212 22 K 166 to 400 F 60 220 F 9261T62 233 70 15 Chisel Tip Probes tar dia with 3 ft PVC Cable J 40 to 2500 220 F 39105K511 89 45 K 40 to 500 F 220 F 39105K512 89 45 T 40 to 500 F 220 F 39105K513 89 45 16 PFA oated Round Tip Probes Me dia Jwe Type 304 SS Cable 325 to Ja 12 9260T31
19. ee 183 6 4 LOAD CALCULATION S P Pee AE eae TERCERO SEHE ee ees 184 6 5 CABLE MASS CALCULATIONS e P ts Pe ES ERE RYE HR ERROR ERE ee EE ERE HE E LER e 184 6 6 ELECTRICAL INTERFACE REQUIREMENTG cc cccssssscecssssecssssnsecsssaeeecesssecseaesecsesaeeessesecsesaesecessaeesensnseeses 185 661 Power Interface iiis UR ti RR HIRED IR II ERI a ka 185 602 Dala Interfaces eae aided 185 169 1 ICD Nomenclature DR Dexterous Robot GA Grapple Arm RSS Robotic Servicing System HST Hubble Space Telescope HRV Hubble Rescue Vehicle EE End Effector Flight Releasable Grapple Fixture 170 2 ICD Mechanical Interface 2 1 Structure The EE on the GA is a modified Canadarm end effector that is designed to capture the standard GF that is used on the HST It has two cameras mounted on the exterior of the EE Only one will be used during docking and the second is available to provide a backup in case the primary camera fails The cameras are angled 120 away from each other around the EE with the same relative vertical position and orientation The 120 offset is derived from the symmetry of the cams in the GF If the primary camera fails during docking with the HST the EE can rotate 120 and the backup camera will switch on In this new configuration the tracking system can use the visual data as before
20. 11 A ro UU i 0 EX El 1 Ex ESL ES ES ES 5 5 5 5 1 5 1 15 5 51512 1215 121515121215 IAIN AISI ASIN es a lt lt lt lt core ageso kd Pe OON ON HH dg ro 5 63 Ja Ja a jo 0 5 gt 9 23 5 5 5 5 3 35 5 5 3 3 25 3 35 2 2 2244 om TNT p 11111 111111 11111111111 55 ANANAS 555555555555 555 agQRisag MRR SS SS STi a W NSSSSSSSSSSSSSSSSSNSSSSNSNSS A 125 RT I SSSS SS rz gt SSSSS By gt a 2 SSSSSONSSSSSS a 7 lt 555555 SSSSSSSS ulao ia O 1 RX Sa gt gt SSSSSSSSSSSSS 2 1 DR Body 126 Appendix 7 2 Electrical Functional Block Diagram Appendix 7 2 1 High Level EFBD 5 2 o QD 2 g 3 o a gt c o o o o x c 2 29 E 9 8 8 8 9 2 5 m oz B SEs 8 o ESS ESS RES MESS RN SENSN RUSS
21. 16 PCO VSS i4 15 STB RST TS SOP 24 TS SOP 28 06 04 Rev B Copyright 2004 EM Microelectronic Marin SA www emmicroelectronic com EM6607 EM6607 at a glance Power Supply Low Voltage low power architecture including internal voltage regulator 1 2V 3 3 V battery voltage 1 8pA in active mode 0 5pA in standby mode in sleep mode 1 5V 32kHz 25 C 4 Bit Input Output PortE 32 kHz Oscillator or external clock Separate input or output selection by register Pull up Pull down or none selectable by metal mask if used as Input 4 Bit Input Output PortD Input or Output port as a whole port Pull up Pull down or none selectable by metal mask if used as Input CMOS or N channel open drain mode Serial Write Buffer clock and data output RAM 96 x 4 bit direct addressable ROM Q Serial output Write Buffer 2048 x 16 bit metal mask programmable max 256 bits long clocked with 16 8 2 1kHz automatic send mode a CPU interactive send mode interrupt request 4 bit RISC architecture when buffer is empt 2 clock cycles per instruction 72 basic instructions Q Buzzer Output if used output on PBO 24 pin or PEO 28 pin Main Operating Modes and Resets 3 tone buzzer 1kHz 2kHz 2 66kHz 4kHz TBC Active mode CPU is running Standby mode CPU in Halt Prescaler Sleep mode No clock Reset State Init
22. 4 3 3 2 4 3 3 3 4 3 3 4 4 3 3 5 4 3 3 6 4 3 3 7 supposed to install All tools shall be capable to tolerating the maximum force applied by the DR The DR shall be capable of acquiring the required tool as necessary for each operation The DR shall be capable of fastening the tool to its appropriate arm in a secure manner The DR shall be capable of using its end effector to apply the required force torque to operate the tools The DR shall be able monitor torque revolutions monitor the progression of the tool The DR shall ensure that all tools are safely stowed away after completion of use not floating around as it might damage the HST or cause other unwanted complications 4 3 4 The DR and GA will be able to perform self diagnostics to identify malfunctions 4 3 4 1 4 3 4 2 4 3 4 3 4 3 4 4 4 3 4 5 4 3 4 6 4 3 4 8 The DR software shall have appropriate algorithms to communicate with the sensors to check status before or during operations The DR sensors shall be capable of checking the internal circuits of the GA DR The HRV shall be capable of checking the on board processor functionality The DR shall be able to verify whether all its actuators are functioning The DR software shall be capable of checking the control software before the control commands are executed The EM C amp DH shall be able to verify that communication link is established with both GA and DR The DR GA will communicate self check results to Groun
23. 4 Mb EEPROM vs 8 Mb EEPROM on AD AE amp AF Models Doc Rev 4 Page 2 of 5 MICROELECTRONICS SCS750A SCS750A Block Diagrams SCS750A Block Diagram Rad Tolerant FPGA Reed Solomon TMR Protected SEU Immune PowerPC SDRAM 256 MBytes System Controller Memory Controller PCI Timers Interrupts DMA UART Reed Solomon EDAC EEPROM 8 MBytes PowerPC PowerPC Triple Modular Redundancy Local PCI Bus 32bit33 MHz 5 5 21 227 WIS ERAGE PCI PCI Bridge 32 bit 33 MHz cPCI USRT x2 MIL STD 1553 Programmable Timers x3 BC RT MT 32 Programmable 1 0 Rad Tolerant FPGA SEU Immune Engineering development Rad Tolerant FPGA SEU Immune use only SEU Immune Triple Modular Redundancy Protection TMR Processor SEU Flush TMR Processor Restore PowerPC PowerPC PowerPC PowerPC PowerPC PowerPC Detects upset Scrubs memory contents Flushes memory into main memory Restores memory back into pProcessors Tri states upset pProcessor i Resynchronizes all three Processors into lockstep Doc 1004741 4 Page 3 of 5 MICROELECTRONICS SCS750A SCS750A Performance Charts Software Selectable Power Consumption Maxwell SCS750A e Typical Rad Hard 750 SBC Performance MIPS Power Consumption Watts Note Peak performance listed is based on
24. Copyright O 2004 EM Microelectronic Marin SA 7 www emmicroelectronic com EM6607 R W Description R W Watchdog timer reset W SLEEP mask bit WD Timer data 1 4 Hz WD Timer data 1 2 Hz Table 3 shows the status of different EM6607 blocks in these three main operating modes Table 3 Internal state in Active Stand by and Sleep mode Peripheral EM6607 mode ACTIVE mode STAND BY mode SLEEP mode POR static On On On Voltage regulator On On On Low Power Quartz 32768 Hz oscillator On On Off Clocks Prescaler amp RC divider On On Off CPU Running In HALT Stopped Stopped Peripheral register On On retain value retain value RAM On retain value retain value Timer Counter On if activated before stopped Supply Voltage Level Det SVLD can be activated can not be activated Off PortA C Reset pad debounced Yes Yes No Interrupts events Yes possible Yes possible No not possible Watch Dog timer On Off soft selectable On Off soft selectable No Analogue Watchdog osc detect On Off soft select if activated before Off 3 Power Supply The EM6607 is supplied by a single external power supply between Vpn and Vss the circuit reference being at Vss ground built in voltage regulator generates Vgec providing regulated voltage for the oscillator and internal logic Output drivers supplied directly from the external s
25. Spindle Spindle Magnetic hard disk Magnetic disk Magnetic head movable Photo sensor Magnetic head CIN Qe Vitaton proof leg Spindle motor SS Electromagnetic brake Fig 17 An example of hard disk drive single disk type from Ref 1 p86 Fig 5 9 Page 12 12 48531 EMS Chapter 12 Brushless DC Motors The hard disk drive works as follows see Fig 17 The surface of the aluminium disk is coated with a film of magnetic material Data is read written by a magnetic head floating at a distance of about 0 5 um from the disk surface due to the airflow caused by the rotating disk and this maintains a constant gap Therefore when the disk is stopped or slowed down the head may touch the disk and cause damage to the magnetic film To prevent this this spindle motor must satisfy strict conditions when starting the stopping Table 4 lists the basic characteristic data of brushless dc motors used in 8 inch hard disk drives Fig 18 Table 4 Characteristics of a three phase unipolar motor designed for the spindle drive in a hard disk drive from Ref 1 p87 Table 5 3 Manufacturer Nippon Densan Corporation Item Model 09FH9C4018 09FH9C4022 Voltage 24 2 4 2442 4 Output 18 22 Rated torque 10 Nm 0 490 0 588 Starting torque 10 184 1 47 1 96 Starting time s 1 35 1 55 Rated speed r p m 3600 3600 Rated current A 2 0 2 4 Temperature 0 50 Stability per cent 1 0 Inertia 1076 kg m 1380 1670 Brakin
26. Technical Information Specifications subject to change without notice MME0603 ACOMPANY OF THE SWATCH GROUP EM MICROELECTRONIC MARIN SA EM6607 Ultra low power microcontroller with 4 high drive outputs Features Low Power typical 1 8 active mode typical 0 5uA standby mode typical 0 1uA sleep mode 1 5V 32kHz 25 C Low Voltage 1 2 to 3 6 V ROM 2k x 16 Mask Programmed RAM 96 4 User Read Write 2 clocks per instruction cycle RISC architecture 5 software configurable 4 bit ports 1 High drive output port Up to 20 inputs 5 ports Up to 16 outputs 4 ports buzzer three tone Serial Write buffer SWB Supply Voltage level detection SVLD Analogue and timer watchdog 8 bit timer event counter Internal interrupt sources timer event counter prescaler External interrupt sources portA portC D OOOOOOOOOOOOOOD Description The EM6607 is a single chip low power mask programmed CMOS 4 bit microcontroller It contains ROM RAM watchdog timer oscillation detection circuit combined timer event counter prescaler voltage level detector and a number of clock functions Its low voltage and low power operation make it the most suitable controller for battery stand alone and mobile equipment The EM6607 microcontroller is manufactured using EM s Advanced Low Power CMOS Process In 24 Pin package it is direct replacement for EM6603 Typical Applications s
27. 1 8 Ground Support assesses information and determines workaround I 1 9 Ground support transmits new instructions 1 10 Shut down 1 11 Boot up in normal mode using primary EPS 1 12 Perform EPS Diagnostic Tests 1 13 Transmit Data to Ground Support 1 14 Resume Normal Operations Appendix 1 2 3 Communications black out due to solar The following scenario details the steps to be done in the event of a total communications failure This is a worst case scenario that can be taken as characteristic of any smaller communication problems 81 3 Communications Blackout Due to solar interference 3 1 Normal Operations 3 2 Communications System Fails 3 3 Complete Current Automated sub task 3 4 Enter safe mode 3 5 RSS Perform Internal Communications System Diagnostics 3 6 Determine failure is due to external causes 3 7 Enter Standby mode 3 8 Ground control determines source of comm failure 3 9 Re route communications to functioning satellite 3 10 Re Establish data connection 3 11 Perform overall Communications system Diagnostics 3 12 Resume Normal Operations 82 Appendix 2 System Requirements Note to the reader Numbering of the requirements is separate from that of the structure of this document and is consistent with the original definition of requirements in our first systems assingnment 4 2 Dexterous Robot derived functional requirements 4 2 1 The DR sha
28. 115 80 325 to 1500 16 2220 9260771 134 40 325 to 500 F 12 550 F 9260T37 115 80 325 to 500 F 16 550 F 9260T77 134 40 490 17 PFA Coated Round Tip Probes 6 dia with 32 Type 304 SS Cable 325 to 500 F 12 9260T33 115 80 325 to 500 F 16 9260T73 134 40 325 to 500 12 9260T39 115 80 325 to 500 F 16 25 9260T79 134 40 18 PFA Coated Round Tip Probes dia wi32 Type 304 SS Cable J 325 to 500 F 12 9260T35 115 80 7325 to 500 F 16 5502 9260T75 134 40 325 to 500 F 12 25 950 F 9260T41 115 80 325 0 500 16 0 25 550 9260781 134 40 19 Hypodermic Tip Probes dia with 554 304 SS Cable 325 to 600 0 2 9262 22 600 9262T24 325 to 41500 F 9262T52 325 to 41500 F 9262T54 325 to 600 9262T32 325 to 600 9262134 325 to 1500 Es js 325 to 9262T62 325 to 1500 F 262764 88 80 c 0 2 550 9 m Hypodermic Tip Probes erd dia with EEA Type 304 SS Cable c c K K K K 325 to 4600 2 F 9262T26 325 to 600 ps 6 9262T28 325 to 41500
29. 4 2 7 3 The DR shall be sufficiently stiff so that stopping distances angles are satisfied 4 2 7 3 1 Stiffness of the Arms and Joints gives how much the stopping distance is extended by elastic deformation 4 2 7 3 2 need to find out how to model budget linear and tortional deflections 86 4 2 7 3 3 Overall stiffness is affected by DR GA structural interface and Stiffness of GA i e how the strength of the DR stacks up on top of the GA Note For details of above calculations see Appendix 5 4 2 8 DR shall be capable of limiting forces normal to constrained translational paths to no more than 1016 and delivering up to 25lbs along those paths 4 2 8 1 Shall have a six axis force and torque sensor near end effector 4 2 8 2 Resolution accuracy of Force Moment at end effector shall be 4 2 8 2 1 at least 2lbs and 4 2 8 2 2 at least 2ft lb 4 2 8 3 actuator commands will be based on feedback from 6 axis sensor to conform to the 1016 2516 requirement 4 2 9 The DR shall have the following interfaces 4 2 9 1 The required structural interface between DR and is the same as 4 1 3 1 1 4 2 9 2 The DR shall be able to interface with the HST in two following ways 4 2 9 2 1 Directly grapple Different Components that include e Harness from conduit to WFC3 e Power cables e Data cables New Ground Strap Stow Fixture WF PCII interface plate blind mate connector Ground Strap A Latch Thermal contamination cover for WFC3 Robotic int
30. 784 28V 176 30 100 300 254 762 am 523 15Wat 28 270 99 100 50 254 170 1 88 529 25Wwa 115V 441 30 10 100 254 240 1 264 50Wat 5V 896 x t0 1500 254 380 1 8 176 1351 30 200 2 00 508 508 AM 55 20Wat 115 390 2 00 3 00 50 8 762 30Wwa 15v 550 30 2 00 40 508 1016 E 331 115 7 41 30 200 600 508 124 1 8 220 60Wat 115V 11 23 2 200 1200 508 Wis 110 120Wat 5V 2269 24 30 3 00 762 762 aw 294 45 15V 841 9 300 5 00 762 1270 176 75Wat 115V 1423 300 1000 762 240 1 882 150 115 2875 24 300 150 762 3810 588 205 Wat 115V 4330 24 4 00 400 106 1016 1 165 80WatitSV 1520 30 400 800 1016 2032 am 827 1601 115 3084 24 40 1200 10 6 308 14E 551 240Wal SV 4648 24 500 500 970 170 17 106 1259 115 240 24 00 1000 1270 2540 1 529 BoWat 115 48 57 24 500 150 1270 310 198 353 375 115 7312 24 10 00 100 2540 240 1 00 264 500 115 9752 20 1000 150 2540 3810 tm 176 750 Wat 115 146 92 20 0 09 127 24 310 250 Wa 5 013 100 599 254 24 31 0 157 5Wat 28V 3 00 0 12 762 31 310 378 35Wat 115V 26 Resistance tolerance is 10 or 0 5 Q whichever is greater Mod Tronic Instruments Limited Tel 1 800 794 5883 Fax 1 800 830 7122 www mod tronic com B 2 HK913P HK913N 30 76 19 18 HK913A HK913B C 13 Dimensions in inches mm The 913 heater kit permit
31. 800 807 9166 Fax 727 573 5918 info micromo com gt www micromo com For notes on technical data refer to Technical Information Specifications subject to change without notice 0402 ENGEL Worm Gearheads 1 133 oz in Motor and Gearhead combinations G2 6 fits motor series GNM3150 G3 1 fits motor series GNM5440 Series 62 68 637 G2 6 amp G3 1 See beginning of the PMDC Gearhead Section for Ordering Information G2 6 G3 1 Housing material metal metal Backlash at no load lt 1 5 lt 1 5 Shaft load max radial Ibs 33 8 45 axial 165 13 5 18 Series G2 6 with Motor Series GNM 3150 length output torque reduction ratio weight with continuous intermittent direction efficiency without motor operation operation of rotation motor GNM 3150 M max max max max reversible Kg Ibs mm in Nm oz in Nm oz in 4 8 1 0 45 0 99 179 7 05 0 7 99 1 7 991 3 82 os 0 45 0 99 179 7 05 1 3 184 1 7 991 3 80 12 1 0 45 0 99 179 7 05 1 6 226 6 7 991 3 80 14 5 1 0 45 0 99 179 7 05 2 0 283 2 7 991 3 78 20 1 0 45 0 99 179 7 05 2 4 339 9 8 1 132 9 70 25 1 0 45 0 99 179 7 05 22 7 382 4 8 1 132 9 66 30 1 0 45 0 99 179 7 05 3 0 424 8 7 991 3 67 36 1 0 45 0 99 179 7 05 2 5 354 0 5 708 1 63 Series G3 1 with Motor Series GNM 5440 engt output torque reduction ratio weight with continuous intermittent direction efficiency without motor operation operation of
32. GA Interface Loads on the GA DR fixture during extreme cases Stopping 1000Ib FOS Equivalent Load fix Linear Force case Distance from force to centre of fixture Torque case Distance from torque centre to centre fixture Applying a 50 ftlb Torque Torque Distance from torque centre to centre fixture Appendix 8 4 Modal Analysis Modal Analysis was performed with SAP 2000 a structural analysis tool available on the Engineering Computing facility at the University of Toronto It performs eigenvalue analysis based on the stiffness and mass matrices associated with the structure e A low fidelity model was created where each Joint was assumed to have 15kg Mass and boom characteristics were entered as follows Section Name FSEC1 Section Properties Property Modifiers Material gt Dimensions Outside diameter 13 Wall thickness tw Display Color Caen Figure 11 1 e Units are Kg cm C 154 Material Property Data Display Color 1 Material Name CarbComp Color Type of Material Type of Design Isotropic C Otthotropic Design None z Analysis Property Data Design Property Data Mass per unit Volume 1 601E 06 Weight per unit Volume 7 849E 03 Modulus of Elasticity 1 937 09 Poisson s Ratio 0 3 Coeff of Thermal Expansion 1 170E 05 Shear Modulus 450E 08 Material Damping Advanced Cancel Figure 11 2 Units
33. Hubble Engineering Repair Operation Final Report Michael Trauttmansdorff Operations Kristian Dixon Controls Stephanie Allen Electrical Mohammad Alam Systems Wassim Abu Zent Mechanical Rev ZG December 6 2004 Acknowledgements Team HERO would like to thank the following people for their help and support throughout the design project Paul Fulford Course Coordinator Tim Reedman Ross Gillett Tim Fielding Perry Newhook Professor Chris Damaren U of T Course Coordinator Luke Stras Dr Chad English Neptec II Executive Summary The Hubble Rescue Mission 2 planned by NASA has a primary objective to safely and reliably de orbit the Hubble Space Telescope HST and a secondary objective to extend the useful scientific life of the HST The mission will be performed by a Hubble Rescue Vehicle HRV which is to consist of a De Orbit module DM which de orbits the HST and an Ejection Module EM which supports the Grapple Arm GA and Dexterous Arm GA and de orbits them after the servicing phase is complete The following high level requirements of a robotic servicing mission have been put forth from NASA Head Quarters 1 Provide the capability to safely and reliably de orbit HST at the end of its useful scientific life 2 Provide the capability to robotically extend the scientific life of HST for a minimum of 5 TBR years 3 Provide robotic installation of the WFC3 and COS instruments 4 Prov
34. J jacobian Xv thetav C1 x gt matrix 3 3 1 0 0 0 cos x sin x 0 sin x cos x C2 x matrix 3 3 cos x 0 sin x 0 1 0 sin x 0 cos x C3 x matrix 3 3 cos x sin x 0 sin x cos x 0 0 0 1 1 x matrix 3 3 1 0 0 0 cos x sin x 0 sin x cos x C2t x matrix 3 3 cos x 0 sin x 0 1 0 sin x 0 cos x C3t x matrix 3 3 cos x sin x 0 sin x cos x 0 0 0 1 162 V V V V V VV V gt 16 matrix Location of each joint arm length segments 11 1 3 1 0 15 0 0 12 matrix 3 1 0 85 0 0 13 matrix 3 1 0 85 0 0 14 matrix 3 1 0 15 0 0 15 matrix 3 1 0 15 0 0 3 1 0 15 0 0 gt gt TIP RESOLUTION ANALYSIS V V VV V V V V V V V V VV V VV VV VV VV V V VV V V VV gt Resolvers give 4arcminutes Controls Assignment 4 Minutes 4 360 60 PI 180 radians 0 0000032321 radians 1 degree 0 0174533 radian Pi 180 radian http www onlineconversion com angles htm Vary these to produce different configurations thetal theta2 theta3 theta4 theta5 theta6 Vary these to introduce joint errors deltal delta2 delta3 delta4 5 delta6 0 Pi 180 0 Pi 180 0 Pi 180 0 Pi 180 0 Pi 180 289 P1 180 0 0000032321 20 0000032321 0 0000032321 0 0000032321 0 0000032321 0 0000032321 CommandedEEPos evalf evalm matrix 6 1 X1 X2 X3 sols 1 sols 3 thet
35. 07 7 0 086 29 06 5 1E 06 8 3 06 8 8 08 DettaPsil 1 3E 05 6 5 08 1 0 04 19 04 1 9E 04 10 04 10 04 3 3 06 DettaPsi2 1 9E 05 9 7E 06 9750 8 7E 08 07 06 97 06 9 7E 06 1 3E 05 DeitaPsi3 i 5E 06 3 2E 06 1 8 04 185 04 186 04 1 8 04 3 2E 06 f O 0 0E 00 1 3 E 4 4E 06 DeitaY 1 3E 05 gE E 07 2E 24 06 Deitaz 2 7 5E 07 2 2 07 8 3E 06 De taPsi1 2 6 5E 08 1 9 04 E 1 9E 04 DettaPsi2 9 7E 06 7 7 7 7 9 7E 06 DeitaPsi3 Li 3 2E 08 1 8E 1 8E 04 DetaPs 1 Y is negative of XxZ See mmod rev4 mws for maple code used in this analysis DettaPsi2 DeitaPsi3 Maple Code restart with linalg The three principal rotation matrices gt gt gt gt gt 3 3 1 0 0 0 0 1 161 VVVVVVVV VV VV VV VV VV VV VV VV VV POV V V V V V V V V V V V V V V V VV V V V V V VV VV VV VV VV VV VV VV pn ll C2 x matrix 3 3 cos x 0 sin x 0 1 0 sin x 0 cos x C3 x matrix 3 3 cos x sin x 0 sin x cos x 0 0 0 1 Cit x matrix 3 3 1 0 0 0 cos x sin x 0 sin x cos x C2t x matrix 3 3 cos x 0 sin x 0 1 0 sin x 0 cos x C3t x matrix 3 3 cos x sin x 0 sin x cos x 0 0 0 1 C1 x matrix 3 3 1 0 0 0 cos x sin x 0 sin x cos x C2 x matrix 3 3 cos x 0 sin x 0 1 0 sin x 0 cos x C3 x
36. 5 2 2 3 4 Grapple right angle tool from caddy 5 2 2 3 5 Move Tool Arm End Effector into position inside diode box 5 2 2 3 6 Remove P8A connector from diode box 5 2 2 3 7 Connect P8A connector to interface plate 5 2 2 3 8 Repeat P8A ops for P6A connector 5 2 2 3 9 Stow right angle tool in caddy 5 2 2 3 10 Stow any remaining fixtures 5 2 2 3 11 Close diode box V2 5 2 2 3 12 DR standby 5 2 2 3 13 GA standby 5 2 3 Diode Box V2 5 2 3 1 Attach connector interface plate 5 2 3 1 1 Activate GA 5 2 3 1 2 Activate DR 5 2 3 1 3 Move GA DR to diode box opening fixture stow site 5 2 3 1 4 Grapple V2 diode opening fixtures 5 2 3 1 5 Open V2 diode box 5 2 3 1 6 Stow opening fixtures 5 2 3 1 7 Move GA DR to conduit connector plate stow site 5 2 3 1 8 Remove connector stowage fixtures 5 2 3 1 9 Grapple connector 76 5 2 3 1 10 Install conduit attachment point to DBA II 5 2 3 1 11 Stow any remaining fixtures 5 2 3 1 12 DR standby 5 2 3 1 13 GA standby 5 2 3 2 Attach cabling harnesses to HST handrails 5 2 3 2 1 Activate GA 5 2 3 2 2 Activate DR 5 2 3 2 3 Attach Cable 4 points repeated 5 2 3 2 3 1 Move GA DR to harness attachment work site 5 2 3 2 3 2 Acquire a clip tool from tool caddy 5 2 3 2 3 3 Attach harness to rail using a clip tool 5 2 3 2 4 Stow any remaining fixtures 5 2 3 2 5 DR standby 5 2 3 2 6 GA standby 5 2 3 3 Complete diode box power connection 5 2 3 3 1 Activate GA 5 2 3 3 2 Activate DR 5 2 3 3 4 Grapple right angle tool fr
37. 500g O O O 0 4 2 2 2 The DR shall attach the harness from the conduit to the HST handrails 4 2 2 2 1 The DR shall grapple the Harness Attachment Tool e The Harness Attachment Tool shall meet the requirements for the DR End Effector Interface 83 4 2 2 2 2 The DR shall use the Harness Attachment Tool the specially designed clip to harness the conduit in position 4 2 2 3 The DR shall connect the HST s SA3 power to the DM batteries via the new harness 4 2 2 3 1 The DR shall grapple the DBA Connector Tool e The DBA Connector Tool shall meet the requirements for the DR Tool Interface 4 2 2 3 2 The DR shall move the DBA Connector Tool to the work site e Harness Attachment Tool assumptions o mass 5 kg 4 2 2 3 3 The DR shall use the DBA Connector Tool e The tool shall grapple the connector The tool will remove the connector from the DBA II tool will attach the connector to the DBA II Connector Interface Plate The tool will release the connector 4 2 3 The DR shall perform the following actions to complete the WFC3 change out 4 2 3 1 Remove ground strap and clamp it to handrail 4 2 3 2 Install WF PC2 Interface Plate 4 2 3 2 1 Acquire and grapple WF PCII interface plate 4 2 3 2 2 Position WF PCII interface plate 4 2 3 2 3 Install interface plate by driving guide stud interfaces on it into the guide studs on the WF PC2 4 2 3 2 4 use 7 16 hex tool to bolt interface plate in position 4 2 3 3 WF PC2 Blind Mate Release 4
38. 80 APPENDIX 1 2 CONTINGENCY SCENARIOS 80 Appendix 1 2 1 Mechanical failure of the 7 16 80 Appendix 1 2 2 Failure of the main power 61 Appendix 1 2 3 Communications black out due to solar eee nennen 61 APPENDIX 2 SYSTEM 83 APPENDIX 3 SYSTEM ARCHITECTURE eoo oae Vou se se Un reae Ua See ud 91 APPENDIX 3 1 SYSTEM BLOCK 91 APPENDIX 4 FAILURE MODE EFFECTS ANALYSI scccccsssssssscscccccsssssscssceccscesssssscseceoees 92 APPENDIX 4 1 FREQUENCY AND SEVERITY RATINGS FOR FMEA 00 0 cccccccecsececesssececeeseeeecseceseesueeeceesaeeeseneeeees 93 APPENDIX 5 gt 5 94 APPENDIX 5 1 LEVEES OF AUTONOM Y sa cicer pn ei ette 94 APPENDIX 5 2 COMMAND AND CONTROL FLOW enne enne nere enn sienne 94 APPENDIX 6 EOD HUS P 103 11 1 103 11 2 PLANT AND CONTROLLER BLOCK 2 412422 02 0 00010000000000000000000000000000000 nenne
39. For notes on technical data refer to Technical Information Specifications subject to change without notice 0402 Appendix 10 Interface Control Document HERO amp Frontier Robotics Interface Control Document HERO Michael Trauttmansdorff Operations Mohammad Alam Systems Stephanie Allen Electrical Kristian Dixon Propulsion Orbital Dynamics Wassim Abu Zent Mechanical Frontier Robotics Mark Baldesarra Systems Bruce Cameron Operations Nicolas Lee Software Filip Stefanovic Propulsion Control Brendan Wood Mechanical Rev A October 21 2004 168 ICD Table of Contents 1 NOMENCLATURE D Y 170 2 MECHANICAL INTERFACE 5525 iae eso ee eo po va tuas ees Sopa Pe Pao vUa EE eo Po ERE a Re 171 2 1 SIRUCI REA tet euni PRI ADU c du ML uM LEE UT 171 2 2 DR STOW CONFIGURATION sccccccsssscecssscececseeecssaececsaeecsesueeecsesaeeeceeeeeeesueeecseaaececsueeecsesaeeecsesaeeesseeaeeees 171 2 3 CAPTURE ENVELOPE csssccccececsesssstcesecccsessesceesececsessnseseccesessuaneesecsecesenaeteccesesessuaeseeeccesesseaeeeceeeesensnanes 172 2 4 LOADING Siete 172 2 5 TEHIBRIMEA T certe pt Sentus rte 172 ELECTRICAL INTERFACE coccccsciccssssicccecessssessessccoscssccecssesescoccsscsuesbesvecoocssssesssesvsccscessssessesveccsess 173 4 SOFTWARE INTERFACE sccscsissscessss
40. Sensitive drum Polygon mirror Laser beam A ee Fig 14 Role of motors for laser printers right a brushless dc motor driving a polygon mirror and above how to scan laser beams from Ref 1 p82 Fig 5 3 Page 12 10 48531 EMS Chapter 12 Brushless DC Motors Stack PON Cleaning plate AC disch Pol i Positive electrifier uL Imaging lens Positive electrode lt Processor Electrode roler Semiconductor laser Full scale exposure Fig 15 Principles of laser printers from Ref 1 p82 Fig 5 4 Fig 16 Brushless dc motor for a laser printer from Ref 1 p83 Fig 5 5 Table2 Characteristics of three phase bipolar type brushless motors Manufacturer Nippon Densan Corporation Item Model 09PF8E4036 Voltage V 24 1 2 Output W 36 Rated torque 10 Nm 0 294 Starting torque 107 Nm 0 588 Starting time 6 3 at non inertial load Rated speed r p m 6000 9000 12 000 selection Rated current A 3 5 Temperature 5 45 Stability per cent 0 01 Three phase A connection A non inertial load is a load applied by using a pulley and a weight Page 12 11 48531 EMS Chapter 12 Brushless DC Motors Hard disk drive As the main secondary memory device of the computer hard disks provide a far greater information storage capacity and shorter access time than either a magnetic tape or floppy disk Formerly ac synchronous motors were used as the spindle motor in flop
41. To move the arm the GC will upload desired Dx Dy Dz and Dq1 Dq2 to the DR CPU The CPU will then calculate the desired motor angles and command the motor micro controllers to rotate the motor The motors will have resolvers that are will used to identify the amount of turn This data will be fed back to the micro controller to form a closed loop feedback This data will also be fed back to the main CPU and transmitted to GC While moving the arm the CPU continuously uses real time readings from the collision detecting IR sensors so that the minimum clearance from the HST is not violated In the case that the IR sensors detect a violation the CPU will command the micro controllers to immediately halt all power supply to the motors Fine tuning of end effector position will be done at GC with the feedback of the mini cameras and the LCS once the end effector is in workspace vicinity 6 2 3 2 LCS Motor Control The LCS will have 2 degrees of freedom a yaw motor and a pitch motor Since the GA will not be fully rigid GC will have to register the position of the end effector before a move to generate the Dx Dy Dz Dql Dq2 Dq3 and after a move to ensure correct positioning and apply corrections if necessary Once the motion is complete and the end effector is in position the LCS will be used to register the workspace for servicing operations The LCS motors will be controlled using motor angles as input The resolvers will form the
42. and large quantities of rad hard memory are unavailable the DR software must be designed such that it does not overwhelm the resources of its supporting hardware This imposes limitations on operations that require large computational power and especially impact vision systems activities We have determined that the most computationally significant operation carried out by the DR software is the registration of the workspace using the LCS The LCS scans the workspace and generates a 3D model of the workspace The workspace is then registered using model matching which is an iterative and computationally intensive process Due to this factor we decided to have a separate CPU for vision system We will need to store quite a large bit of data for the operation especially when handling the model matching as a result we need a high volume of data storage space Typical model matching applications being researched at Princeton University 12 needed 256 MB of RAM The CPU and memory requirements led to the choice of the SCS 750A computer by Maxwell Corporation Operating at 800 and accompanied by 64KB of L1 cache and 256 KB of L2 cashe and 256MB of RAD hardened SDRAM Capabilities of CPU have to be chosen based on software complexity and will determine the power required by the CPU This will impose requirement on our power budget The Maxwell CPU and Memory board requires 7 25 W of power depending on the clock rate and MIPs requirements For r
43. facilitate capture by the tool end effector A diagram of the tool caddy with the tools loaded can be found in Appendix 8 1 8 3 6 Thermal 8 3 6 1 Requirements The thermal control system TCS needs to keep the DR in the survival range at all times when off and in the operational temperatures at all times when it is on These temperature ranges are given in Table 8 6 Operational mode C Survival mode C Power Fuses 10 to 20 15 to 35 C amp DH 20 to 70 40 to 85 Electronic components 20 to 65 50 to 70 Joint actuators 20 to 70 65 to 80 End effector actuators 20 to 70 65 to 80 Camera sensors 20 to 65 50 to 70 Structure 15 to 65 45 to 65 Table 8 6 Operational and Survival Temperatures This imposes that the EM provide power to the DR thermal system when the DR is stowed This will occur through dedicated keep alive connectors on the DR 8 3 6 2 Design The TCS isolates the DR from space by using a MLI blanket The MIL blanket is painted white on the outside to minimize the heat absorption when the sunrays are in direct exposure The MIL blanket results in a reduced radiation heat loss from the DR body making the net power requirement for all of the heaters 20 W The detailed calculations have been included in Appendix 8 5 To have an approximate duty ratio of 70 we design the heaters to have a maximum capacity of 30 W When requiring a 20 W average power the duty ratio
44. feedback loop GC will control the orientation of the LCS view The motor micro controllers will receive the following commands e Move Joint at speed X 30 e Move Joint to angle X e Apply Force X to Joint The motor micro controllers will give the following commands Control signals to the internal hardware release brakes voltage to motors read sensors Position Rate Torque telemetry to the CPU and ground control 6 2 3 2 1 Level of Autonomy The motor controllers perform some autonomous operations in that they operate as closed loop feedback system They operate until they achieve the desired position rate force given by the controlling actor GC or DR CPU 6 2 3 2 2 Performance Impact The low level autonomy in the motor units increases reliability and responsiveness to input commands as there will not be any internal processes that could cause a control lock Additionally it allows various agents to control the same physical mechanism while still providing a sufficient level of abstraction which encapsulates the details of internal hardware and electronics 6 2 3 3 Control torque applied by end effector motor Ground control will determine the torque to be applied to the tool The processor will receive the required torque via the communications and pass the data to the micro controller This will determine the duty ratio of the pulse width modulation that is applied to the motor drive circuits The motor drive circuit
45. jeubis U 5 pue eeg uonensibe 2 now Ajnuapi 40 20 uoneoo 0409 20 OL w ret oup punoJc sloppy Kuiouojny uonisogd 0 33 jo siene1 MO 4 YSE UOISSIA 95 4 pee ee eee m 9 Mission Task Command Flow Levelsof 1 DR Collision Avoidance Autonomy 2 Actors Command Events DR Collision Gather Data based on Execute emergency stop Controller model evaluate if collision is YE maneuvers stop GA and about to occur T DR Vision Grab most recent frame of System LCS data Processor DR Collision Avoidance Sensors 96 Mission Task Command Flow Levels of DR manual operations Autonomy 2 Actors Command Events Initiate manual move command Send manual move command signal repeat until acknowledged DR GC Continuous poll reciever for result of manual operation Send move to angle command to specific motor Couey for micro controller and repeat Transmit vee of manual DR Main CPU until command is knowl computer Seen DR Motor Controller X Command motor
46. without motor operation operation of rotation motor GNM 2636A M max M max max reversible Kg oz mm in Nm Ib in Nm Ib in 180 1 0 74 26 1 187 5 7 38 10 5 92 9 20 177 0 80 216 1 0 74 26 1 187 5 7 38 10 5 92 9 20 177 0 80 293 1 0 74 26 1 187 5 7 38 10 5 92 9 20 177 0 80 352 1 0 74 26 1 187 5 7 38 10 5 92 9 20 177 0 80 450 1 0 74 26 1 187 5 7 38 9 79 7 18 159 3 80 MicroMo Electronics Inc 14881 Evergreen Avenue Clearwater FL 33762 3008 Toll Free 800 807 9166 Fax 727 573 5918 info micromo com gt www micromo com For notes on technical data refer to Technical Information Specifications subject to change without notice MME0603 ENGEL Series GP48 2 Dimensional outlines for GP48 2 with GNM2636 amp GNM2670 KEY DIN 6885 045 4x4x18 1 772 BRAKE B11 ao OPTIONAL 300 12 011 11 811 472 079 29 984 GNM 26 G48 2 4x M5 10 394 DEEP Front View MOTOR TYPE RATIO DIMENSION L1 L2 GNM 2670 A 5 1 7 66 1 198 7 795 58 2283 GNM 2670 A 21 1 59 1 2145 8445 745 2 933 GNM 2670 A 94 1 150 1 2315 9 114 91 5 3 602 GNM 2636 A 180 1 450 1 187 5 7 382 91 5 3 602 MicroMo Electronics Inc 14881 Evergreen Avenue Clearwater FL 33762 3008 Toll Free 800 807 9166 Fax 727 573 5918 info micromo com gt www micromo com For notes on technical data refer to
47. 0 07 20 8 mm 6 01 to 12 15010 300 006 21 5 mm Over 12 300 mm 0 17 43 0 mm Custom options Custom shapes and sizes to 10 x 22 250 x 560 mm with FEP adhesive 12 x 72 300 x 1830 mm with WA ULA Custom resistance to 450 Q in 70 Yem WA or ULA adhesive see page A 8 preferred for custom designs below 150 C Available with surface mount sensors connectors even integral controllers TUV or UL approval is optional Tighter resistance tolerance See section J for custom design assistance 1 Mod Tronic Instruments Limited Tel 1 800 794 5883 Fax 1 800 830 7122 www mod tronic com These heaters are normally available from stock for Type configuration immediate shipment Voltage and wattage values are for reference only Heaters may be operated at other Y voltages if they do not exceed the maximum allowable EN vx watt density ratings 1 See section D for these and other models with LEAD LENGTH TAB DIMENSIONS additional ordering options 12 305 mm 30 0 40 0 25 102 x amp 4 mm Greater selection of resistances AWG 24 26 047 x 040 102 x 10 2 mm e Variable lead length More backing options UL recognition How to order stock heaters 1050 29 127 508 157 5Wa 20V 09 30 0 400 127 106 aM 784 10Wat 28V 1 67 30 0 600 127 1824 i 523 15Wa 28V 235 x 10 254 157 Wa 28V 08 3 100 200 254 508
48. 0 2 2 Controlled Devices aD eta e e AT AG e ER e Race ete qe aan 29 0 2 3 Controller OVeFVIEW ade e e E RR e ei n T rex aes 30 6 3 VISION SYSTEM ARCHITECTURE ecd deti 33 6 3 1 Selection of a Primary Vision System 33 0 3 2 Video Cameras ud vocem ee V WR Ton t e RD aa ee ee ace 36 6 5 32 VisiomtSysteni CPU t Aeneane ee teh e ede eiie utram mad 36 6 4 SOFTWARE ARCHITECTURE csi secs eterne i ua Meses inei eee 37 6 4 1 Software Requiremen s atte Tee a ee dp rtg E tege tede ete ea mere ep a tees 37 042 Level O socias e a RT RR n e mee ead 39 64 3 Level T Breakdown anta eau eee date RU WR RE nta As e Nie han aaa 41 0 444 Level 2 breakdown excea ee eben da etes ee eee eoe adh esti oe gon 45 049 Example Software Mini Spet sirine a etate me t urere eren 46 040 Data Dicti ndtyss i pat deett adn dnte eed 46 6 4 7 Software Push Down Hardware Requirements eese eene 48 ELECTRICAL 5 8 255 eed eo ee ae Ve en Pena ae eR eene Sepe oa 49 7 1 BEEGTRIGAT REQUIREMENTS irte tie eter ie ta ia 49 7 2 BEEGTRICAT ARCHITECTURE a ttti iei a A im Eie ep d vim tie o cana 49 7 2 1 SfxteralInteraces i dte epe drea rd er a
49. 1 90E 11 Pa 1570 kg m 3 433714285 7 Pa 1 1E 11 Pa 4700 kg m 3 55142857 14 Pa 7 10E 10 Pa 2700 kg m 3 Minimum strength for Bending minimum Bending Moment Radius Bending stress capability Segment carbon Titanium I Aluminium Radius tcarbon t Titanium t Aluminum Upper Boom 1 61E 07 4 23E 08 3 33E 07 0 075 0 0001 3 2E 05 Lower Boom 8 03E 08 2 11E 08 1 66E 07 0 075 0 0001 1 6E 05 Wrist 3 65E 08 9 61E 09 7 56E 08 0 075 0 0000 7 3E 06 Minimum Strength for Allowed Deflection BENDING MaxNetDeflection 0 002 m l M L 2 2 E MaxDeflection Max Deflection carbon Titanium Aluminium Radius t carbon t Titanium t Aluminum 0 0002 3 11E 05 5 37E 05 8 32E 05 0 075 0 0235 0 0405 0 0628 Upper Boom 0 0007 1 10E 05 1 90E 05 2 94E 05 0 075 0 0083 0 0143 0 0222 Lower Boom 0 0007 5 49E 06 9 48E 06 2 55E 05 0 075 0 0041 0 0072 Wrist 0 0004 4 71E 06 8 14E 06 1 16E 05 0 075 0 0036 0 0061 Note All these materials can easily handle the required loads However it is desireable to produce beams with higher moments of inertia than the calculated minimums to produce a stiffer arm The stopping distance budget allows for a net displacement of 151 Appendix 8 3 7 Motor and Gearbox Calculations Tool Arm Shoulder Roll 222 0 676 1 00 39 15000 0 6 06 44 8 15000 Shoulder Pitch 2220 676 1 00 39 15000 0 6 06 44 8 15000 Elbow Pitch 1356 400 1 50 35 9000 06 06 41 9 13500 Wrist Pitch 1356 124 150 3
50. 2 3 3 1 Identify and reach blind mate connector 4 2 3 3 2 Release blind mate connector 7 16 interface 4 2 3 4 Release and Secure Ground Strap 4 2 3 4 1 Grapple ground strap 4 2 3 4 2 Release ground strap 7 16 hex interface 4 2 3 4 3 Install ground strap on GS temporary stowage fixture 7 16 hex interface 4 2 3 5 Release Latch A 4 2 3 5 1 Locate released Latch A 4 2 3 5 2 Verify Latch A has been removed 4 2 3 5 3 Grapple it and bring it into position 4 2 3 5 4 Secure it into position 7 16 interface 4 2 3 6 Remove and Stow WF PC2 4 2 3 6 1 Grapple WF PC2 grappling fixture on the interface plate 4 2 3 6 2 Linearly retract WF PC II 7 5 in the plane of WF PC II 84 4 2 3 6 3 Move WF PC II to stowage location on EM 4 2 3 6 4 Secure WF PC II on EM to prevent it from floating away 4 2 3 7 Retrieve and Position WFC3 4 2 3 7 1 Locate and reach WFC3 storage housing bay on EM 4 2 3 7 2 Remove retract WFC3 thermal contamination protection cover on EM 4 2 3 7 3 Locate and release ground strap on EM 4 2 3 7 4 Release Latch A on EM 4 2 3 7 5 Verify release of latch A 4 2 3 7 6 Grapple robotics interface on WFC3 4 2 3 7 7 Pull WFC3 out of storage housing bay 4 2 3 7 8 Move it into position ready for installation 4 2 3 8 Install WFC3 into HST 4 2 3 8 1 Stabilize WFC3 4 2 3 8 2 Align WFC3 with is guide rails 4 2 3 8 3 Verify proper alignment o Shall be done with camera on DR gripper arm mini Cams 4 2 3 8 4 Push WFC3 into WFC3 enclosu
51. 2 port A interrupt request tvar 3 4 4 port A 3 input 3 port A interrupt request event counter input 5 port E 0 input output O port E buzzer output in 28 pin package 5 6 port B 0 input output 0 port B buzzer output in 24 pin package 6 7 port B 1 input output 1 port B 7 8 port B 2 input output 2 port B 8 9 port B 3 input output 3 port B 10 port E 1 input output 1 port E 9 11 test test input terminal for EM test purpose only internal pull down 10 12 Qou osc 1 crystal terminal 1 11 13 Qin osc 2 crystal terminal 2 input Can accept trimming capacitor tw Vss 12 14 Vss negative power supply terminal 13 15 STB RST strobe reset status uC reset state port B C D write 14 16 port C 0 input output O port C interrupt request 15 17 port C 1 input output 1 port C interrupt request 16 18 port C 2 input output 2 port C interrupt request 17 19 port C 3 input output 3 port C interrupt request 20 port E 2 input output 2 port E 18 21 port D 0 input output 0 port D SWB Serial Clock Output 19 22 port D 1 input output 1 port D SWB Serial Data Output 20 23 port D 2 input output 2 port D 21 24 port D 3 input output 3 port D 25 port E 3 input output 3 port E 22 26 RESET reset terminal Active high internal pull down 23 27 internal voltage regulator Needs typ 100nF capacitor tw Vss 24 28 positive power supply terminal Table 1 Pin Description 06 04 Rev B Copyright 2004 EM Micr
52. 5 2 2 Diode Box V2 5 2 3 Diode Box V2 5 3 WFC3 Operations 5 3 1 Remove Ground Strap 5 3 2 Remove and Temporarily Stow WF PC2 5 3 3 WFC3 installation 5 3 4 Permanently Stow WF PC2 5 3 5 WFC3 Support Hardware 6 EM Jettison and De Orbit 6 1 DR shutdown 6 1 1 Activate GA 6 1 2 Activate DR 6 1 3 Move GA DR to DR stow site on EM 6 1 5 Configure DR for stowage 6 1 6 GA Positions DR in large capture envelope of main stow fixture 6 1 7 GC engages main stow fixture aligning DR with other fixtures 6 1 8 GA tilts DR to position it within capture envelope of remaining stow fixtures 6 1 9 GC engages remaining stow fixtures as required 6 1 10 DR shuts off power completely 6 1 11 GA releases DR 6 1 12 GA standby 6 2 GA shutdown 6 3 EM Jettisons and Carries out De Orbit maneuver Upon the completion of primary and secondary mission objectives the Ejection Module carrying the RSS will be disposed via separation and subsequent de orbit The HST will continue to produce useful scientific data for an expected period of 5 years after the end of the DR mission 5 3 DR GA Interaction This section describes the coordination of the DR and GA operations and explains how the two robots interact The DR and GA will interact in four major ways during the mission 5 3 1 DR grappling and activation The DR will be in keep alive mode until the capture phase of the mission is complete Once the GA is ready it will move to the DR stow
53. A Latch into position As Above 5 3 4 10 DR standby 5 3 4 12 GA standby 5 3 5 WFC3 Support Hardware 5 3 5 1 Activate GA 5 3 5 2 Activate DR 5 3 5 3 Move GA DR to WFC3 Work site on HST 5 3 5 4 Engage blind mate connection As Above 5 3 5 5 Open detector vent valves 5 3 5 6 Mate harness from conduit ECU to WFC3 for RSU 5 3 5 6 1 Grapple connector on harness conduit ESU 5 3 5 6 2 Position circular connector on WFC3 5 3 5 6 3 Complete Connection 5 3 5 5 4 Release harness 5 3 5 7 Mate 1553 bus from RSU to J9 5 3 5 7 1 Open Bay 1 5 3 5 7 2 Acquire RSU tool from caddy 5 3 5 7 2 Uninstall J9 terminator plug 5 3 5 7 3 Stow terminator plug 5 3 5 7 4 Grapple 1553 connector 5 3 5 7 5 Mate 1553 connector with 486 computer 5 3 5 7 6 Return RSU tool to caddy 79 5 3 5 7 7 Close Bay 1 5 3 5 7 DR standby 5 3 5 8 GA standby 5 3 6 Have a smoke and pat self on back Appendix 1 1 6 Jettison Phase Functional Flow 6 EM Jettison and De Orbit 6 1 DR shutdown 6 1 1 Activate GA 6 1 2 Activate DR 6 1 3 Move GA DR to DR stow site on EM 6 1 5 Configure DR for stowage 6 1 6 GA Positions DR in large capture envelope of main stow 6 1 7 GC engages main stow fixture aligning DR with other fixtures 6 1 8 GA tilts DR to position it within capture envelope of remaining stow fixtures 6 1 9 GC engages remaining stow fixtures as required 6 1 10 DR shuts off power completely 6 1 10 2 Shut down Actuators 6 1 10 3 Shut down Sensors 6 1 10 4 Shu
54. Acquire force torque at each joint 1 1 2 Acquire motor health Calculate force and torqure required at each joint using 6D jacobian Translate it into pwm for mosfets controlling current to motor Output PWM values to moto microcontrollers End loop Function power availability command signal unit 1 1 5 Inputs data input motor power requirements Data input power availability Outputs power available for motors Psuedocode Loop Acqure power required Aquire power available Deficit power availab power required qf deficit lt 0 Report to motor command calculator 1 1 4 Else return zero to motor command calculator 1 1 4 End loop 117 Function Overload monitor 1 1 6 Inputs data input force torque at each joint Outputs emmergency stop command Psuedocode Loop Acqure force Torque at each joint For each joint If differnece lt 0 command calcu Else a Difference max load current load Issue emmergency stop command to motor lator Return everythin normal to motor command calcu a 1 118 Appendix 7 Electrical Appendix 7 1 Cable Layout Appendix 7 1 1 Cable Layout Map Layout and Cabling 5 Layout and Cabling 2 Layout and Cabling 1 Tool Arm Layout and Cabling 6 Ejection Module 119 Appendix 7 1 2
55. B Phase orange Hall sensor grey Phase yellow a 5V Logical supply red GND Logical black A Coil winding 3 x 120 MicroMo Electronics Inc 14881 Evergreen Avenue Clearwater FL 33762 3008 Toll Free 800 807 9166 Fax 727 573 5918 info micromo com gt www micromo com For notes on technical data refer to Technical Information Specifications subject to change without notice MME0404 Brushless DC Motors FAULHABER 15 5 Watt with integrated Drive Electronics Series 3153 BRE 009 BRE 012 BRE 024 BRE Nominal voltage 24 Volt No load speed No 5 200 rpm No load current with shaft 0 12 in lo 0 059 A Starting torque Ma 4 67 oz in Torque constant km 6 10 oz in A Slope of n M curve An AM 314 rpm oz in Rotor inertia J 17 104 oz in sec Operating temperature range 0 to 70 32 to 158 C F Shaft bearings ball bearings preloaded Shaft load max shaft diameter 4 0 157 mm in radial at 3 000 rpm 3 mm 0 118 from mounting face 108 oz axial at 3 000 rpm 18 oz axial at standstill 180 oz Shaft play radial E 0 015 0 0006 mm in axial E 0 mm in Housing material mounting face in aluminum housing in plastic Weight 5 75 02 Direction of rotation not reversible clockwise rotation viewed from the front
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57. Data Line Number of connectors for data line 1553 Data Bus 8 Video Line 8 Sensors RS232 8 LCS RS422 4 Total 28 The data lines will need 14 pins for the primary data line and another 14 pins for a completely redundant back up data line system 186 Appendix 11 Class Photo University of Toronto Spacecraft Design Class AER 407 Fall 2004 187
58. Data Sample Calculations Mass R radius of the wire plus insulation L circuit length Rho density of copper 8960 kg m 3 t shielding thickness R bundle bundle radius N drops number of bus drops M drop mass per drop M bus pi R 2 L rho n wires M bundle sum M bus M shielding t 2 pi R bundle L rho M bus drops n drops m drop M total M bundle M shielding M bus drops 140 Appendix 7 5 GA Cable Mass current circuit wire Insulation bundle bundle of required at length diameter thickness wire bundle diameter mass wires interface m mm mm current current mm kg data 1563 8 vdeo 8 DSL 95 411 PWesng surface thickness area mass Number of maae Bundle 1 power 03 02 m Bundle 2 o 3 Ei data 1553 6 we 141 Appendix 8 Mechanical Appendix 8 1 CAD Models DR Front View illustrating tool acquisition opearation 142 5 DR front view Caddy contains 2 columns of clip tools and one column of all the other tools 143 DR Side View 144 Appendix 8 2 Range of Motion Simulation Major arm boom lengths shoulder to elbow and elbow to wrist of 85cm allow clearance of and arm booms and sufficient range of motion for 7 5 of linear translation at tip This arm ge
59. HST allowing the robotic systems to perform the capture and servicing operations 3 4 2 2 De Orbit Module This spacecraft will carry out the primary objective of the HRM namely the controlled de orbit of the HST However prior to this terminal phase of the mission it will serve as the structural attachment between the HST and the EM and thus the RSS It also contains the auxiliary batteries that will extend the functional life of the HST 3 4 2 3 Ejection Module This spacecraft contains the GA and DR robots as well as the electrical power systems EPS communications hardware and new HST components During launch pursuit proximity capture and de orbit the DR is stowed as a payload on the side of this module At the end of the servicing mission this module separates from the HST DM unit and is de orbited along with the on board GA and DR 3 4 2 4 Grapple Arm This robot performs the mission critical capture operation and brings the HRV into alignment for docking with the HST Additionally it serves as the primary platform from which the DR operates during the servicing phase The GA positions the DR at the necessary work sites provides a structural support and is a conduit for the DR s electronics and data cables connecting it to the Ejection Module 4 Dexterous Robot Overview The purpose of the Dexterous Robot DR is to perform three main tasks It must perform power augmentation operation replace the old WF PC2 came
60. LIDAR scan Range 500m 5km 30m 0 1mm lm 2mm 5m 10mm 10m 80mm Range accuracy 1cm 30m FOV 30x30 30x30 Data Rate 10000 50000 point s Unknown Volume 6 10L 15 32L Mass 6 8 kg 12 1 kg Power 35W 65 W Table 6 1 RELAVIS LCS comparison 10 11 A scaled down version of the LCS could be produced that would take advantage of the short range requirement 5m and could operate on the DR s power This would take more development resources than using a conventional camera but given the advantage of being able to operate in any lighting condition the added cost is worth the benefit The field of view FOV would also have to be expanded so that the vision system could keep both arms in view at the same time To complement this FOV expansion the LCS will be mounted on a platform which will allow pan tilt operation 6 3 2 Video Cameras The video cameras produce a standard 2 D image of whatever they are pointed at to provide the vision system as well as ground controllers with a full motion visual representation of the site at which the cameras are pointed The cameras act in response to being turned on via the vision system controller The cameras are low level autonomous constantly producing a stream of video output as long as they are turned on Low level single function autonomy in the cameras increases their reliability as a subsystem and offloads the burden of the low level image capture tasks
61. Solid arrows indicate commands from GC Dashed Arrows indicate autonomously command signals initiated by the DR Thick solid arrows indicate external interfaces with GC Grey blocks are systems and actors external to the DR 5 6 1 Initiation of Mission Tasks Internal Interfaces DR operations such as servicing tasks will be orchestrated by ground control sending combinations of available command types to the DR This methodology can be likened to giving the DR a script to follow and telling it when to carry out a particular line By tailoring the scripts which the DR executes on orbit ground controllers maintain control of the robot at all times but still benefit from its real time control capabilities that it uses while executing a particular given script Typical commands are an EE move where ground controllers could specify a destination point or a constrained path along which the EE should travel For example to remove a bolt ground controllers would first initiate a combined move of the GA DR Then they would have the DR acquire the correct tool Next they would command the DR to position the tool on the bolt an operation that would make use of the DR s greatest on board autonomous capabilities While moving the tool from its original location to its final position on top of the targeted bolt the DR will use its vision system to provide registration calibration of the tool position relative to the target location and correct for any pe
62. Table 3 Frequency Rating Number Description 1 no damage to HST tc HRV trapped to HST Payload collides with HST HRV collides with HST Table 4 Severity Rating Remove control hazard through operational strategies 5 Remove control hazard through design 10 Reduce consequence of hazard Table 5 Control Rating 93 Appendix 5 Autonomy Appendix 5 1 Levels of Autonomy In order to identify the required capabilities of each subsystem of the Dexterous robot we have adopted the following scale for varying levels of autonomy These are based on the levels discussed in the SMAD 9 Level 0 Non Autonomous tasks or commands performed by ground controllers Level 1 The robot runs relatively simple and continuous on board closed loop processes Level 2 The robot can execute planned events and respond to expected inputs based on a stored set of rules and timed commands Level 3 The robot can interpret unplanned sensor inputs and react to unplanned events based on event driven rules and algorithms Level 4 At the fourth level of autonomy spacecraft react to unplanned events not just by executing rules but by using forms of on board intelligence inference engines and planning agents 9 The design of the DR s control and command architecture is such that we generally minimize the level of autonomy required to perform a given task satisfactorily That is we consider a low number on this scale
63. Tasks Manual Automated Operational Command Tasks Grapple DR Deploy DR DR Self Test Performance Asessment Manual operations l e drive a motor Service Operation Grapple tool Move DR EE to target location Have GA move DR to a new Work Site Stow DR GC Communication Tasks Establish Communications Video LCS downlink Telemetry Transmission Update DR software Low level continuous tasks DR Keepalive Initialize Refresh Workspace Registration Collision Fault Detection Emergency Stop Signal Mechanical Sensors resolvers Thermal Control x X X KK KK xxx Table 1 Mission Task Initiators 20 Below is a diagram outlining the subsystems that play a role in the command flow within the DR system It also places them in context with external systems that have command interactions with the DR during its mission Colission Detection System Emergency Stop 2 1 a a ae Thermal NS Controllers Main CPU ics 1 4 System bSystem rapple Arm p es gt y X Vision System CPU Y Communications Link via Ejection Module NASA Mission y 7 Communications Link _ 3 Conmuncaton Controllers t y and Personnel 4 Ground Control GA Ground Control Figure 5 2 Ground Control Architecture
64. are Kg cm C Case 1 Arm with 1000Ib Payload Payload Mass 100016 453 6kg Figure 11 3 Model with Masses indicated OutputCase StepType Eigenvalue Text Text rad sec rad2 sec2 MODAL Mode 1 0 316175 3 1628 19 872 394 92 MODAL Mode 2 0 316175 3 1628 19 872 394 92 MODAL Mode d 0 014653 68 245 428 8 183870 MODAL Mode 4 0 009409 106 28 667 77 445910 MODAL Mode 0 009409 106 28 667 77 445910 MODAL Mode 6 0 001262 792 44 4979 24791000 155 Frequency Analysis Output e Modes 1 amp 2 are 1 transverse Mode 3 is 1 axial Modes 4 amp 5 214 transverse and Mode 6 is 274 axial e For control the important natural frequencies are the transverse ones o 3 1628 Hz o 10628Hz Case 2 Arm with no Payload on EE Figure 11 4 Model with Masses indicated Text Text Unitless Sec Cyc sec rad sec rad2 sec2 MODAL Mode 0 096783 10 332 64 921 4214 7 2 MODAL Mode 2 0 036783 10 332 54 321 4214 7 MODAL Mode 3 0 009285 107 7 676 72 457950 MODAL Mode 4 0 009285 107 7 676 72 457950 MODAL Mode 5 0 004533 217 73 1368 1 1871600 MODAL Mode 0 001216 822 23 5166 6 26694000 Frequency Analysis Output Modes 1 amp 2 are 1 transverse Modes 3 amp 4 are 274 transverse Mode 5 is 1 axial and Mode 6 is 2 axial e For control the important natural frequencies are the transverse ones o 10 332 Hz o 107 7 Hz 156 157 Appendix 8 5 Thermal Control Subsyste
65. away from the Vision System Controller The following commands are received by the video cameras e Vision System Controller Turn On The following commands are given by the video cameras e Control Internal Hardware focus capture image encoding it and transmitting it along the video bus 6 3 3 Vision System CPU The vision system processor is to be designed such that it is to automatically react to requests from GC and CPU for workspace view This reaction involves the vision system processor to command LCS and the mini cams to capture the image of the workspace The vision system processor shall automatically receive LCS and video data directly as soon as the data and the appropriate bandwidth are available The most demanding level of autonomy for the processor is 36 to coordinate the data to calculate the relative coordinate system of each vision field from Mini cams and LCS for meaningful mapping This processed data is to also be fed back to DR CPU and GC upon requests The following commands are received by the vision system processor DR GC Acquire view of workspace DR Request 3D mapping workspace registration The following commands are sent by the vision system processor LCS Capture image e Video Cameras Capture video of workspace 6 4 Software Architecture 6 4 4 Software Requirements The DR software must fulfill a number of fundamental requirements such that it is usable by the HRV ground co
66. background The remainder of the team should be populated with mission specialists payload experts and various management personnel Together this team should be capable of effectively and efficiently coordinating DR operations with other teams in the HRM like the GA and dealing with all situations that arise during the HRV mission 5 6 3 2 Organizational Structure The DR mission control should consist of teams focused on individual mission components will make up the larger DR Ground Control team A mission controller who facilitates interaction between the DR GA and EM will coordinate DR operations DR and GA ground control should be co located to facilitate the effective communication and coordination that will be required during all phases of the DR mission 5 6 4 Existing Support Environment It may be necessary to undergo staff training for this system we assume NASA has the resources and capital needed for this mission Ground operations will require a suitable facility such as the Goddard Space Center which has the necessary communications infrastructure for this mission 5 7 Autonomy This section describes in detail the nature and level of autonomy required of the DR to give an idea of the overall level of autonomy of the mission The reader should gain an understanding of what actions the DR is responsible for initiating in each of its operating modes The tasks 23 performed autonomously by the DR are either ongoing c
67. bay doors and hold objects when the tool needs to clip the conduit or ground strap The EM will also interface during stowage Three stow fixtures will be located on the arm one in the elbow and two in the wrist 61 8 3 2 2 Requirements 1 The DR shall have closed loop accuracy of 0 16 2 The DR motor gear ratio will be sufficiently great to allow minimum input to stack up to required resolution 3 The DR motion should have a resolution of 0 1 inch and 0 1 degree 4 The DR motion should be accurate to 1 degree and 1 inch 5 The DR must be able to stop 100016 mass from the maximum commanded tip velocity within 2 inches and 2 degrees 8 3 2 3 Design The DR general manipulator arm characteristics are listed in Table 8 4 Please refer to Appendix 8 3 for the detailed calculations Main Boom Lengths 0 85 m Arm Diameter 0 15 m Arm Offset from Body Center 0 45 m Total Arm Length 2 2 m Tip Translation Speed 200 Ibs 0 1 m s Tip Rotation Speed 200 Ibs 3 ls Mass structure and motors only 118 6 kg Table 8 4 DR General Manipulator Arm Characteristics As with the tool arm our design utilizes two gearboxes coupled together to provide the appropriate output speed and torque required The motor is attached to a primary worm gearbox which is inherently non backdrivable to eliminate the need for brakes The output shaft of this box is then coupled to a secondary planetary gearbox which completes speed reduction a
68. change the motor speeds over the ranges given in Appendix 8 3 7 7 2 Electrical Architecture 7 2 1 External Interfaces 7 2 1 1 DR to EM During the Launch proximity and capture operations the DR is stowed aboard the EM In order to prevent damage to the electronics the thermal subsystem must be active during these phases To accomplish this the DR will have a primary and redundant electrical connection to EM Both power and data will be transferred by these connectors The power for the DR is drawn from the batteries on board the EM Cables are passed through the GA to two 20 pin connecters at the interface to the DR The DR s main CPU is located on the EM requiring data busses to pass through the GA to the DR micro controllers and components Power and data will both be connected to the DR when it is grappled by the GA 7 2 2 Cabling Layout Cabling will be routed along the exterior of the arms with 0 15 m slack loops at each joint to allow sufficient flexibility of the arm At each drop point a connector will rout the necessary wires from the main bus to the specific EPCE 49 7 2 2 1 Power Cables There will be two primary and two redundant 24V busses for each arm and a primary and redundant 24V pair for the body These 10 5 primary 5 redundant busses will supply power to the joint and gripper motors in the arms the LCS orientation motors and the main LCS unit For the lower power devices there will be two primary and two
69. competitors data sheets and lists their maximum performance Estimated MIPS vs Code Data Size Estimated MIPS Code Data Size KBytes Doc 1004741 4 Page 4 of 5 MICROELECTRONICS SCS750A MICROELECTRONICS SCS750A Techical Specifications RADIATION TOLERANCE 300 Years without an uncorrected upset SEU rate 9 E 6 upsets day Entire board in a GEO Orbit without 1553 TID 100 krad Si Orbit dependent SEL th 80 MeV cm mg All parts except SDRAM 50 MeV cm mg SDRAM PROCESSORS 3 FULLY TMR PROTECTED PROCESSORS PowerPC 750FX on Silicon on Insulator 501 0 13um 2 32 Dhrystone MIPS MHz 1800 Dhrystone MIPS 800MHz 400 to 800MHz Software Selectable Core Clock Rate 50MHz PowerPC Local Bus PROCESSOR CACHE L1 CACHE 32 KByte Instruction with Parity 32 KByte Data with Parity L2 CACHE ORDERING INFORMATION WEIGHT 1 5 Kg 3 3 Lbs Max SCS750AF FLIGHT CONFIGURATION e Rad Tolerant Class S or Equivalent Components Conduction Cooled SCS750AE ENGINEERING CONFIGURATION Rad Tolerant Class B 883 Components Conduction Cooled SCS750AD ENGINEERING DEVELOPMENT CONFIGURATION Commercial Components ACTEL FPGAs Full Hardware amp Software Compatibility w AE amp AF Models Conduction Cooled SCS750AP PROTOTYPE CONFIGURATION Commercial Components Xilinx FPGAs e Similar functionality to AD AE amp AF Model
70. coordinates all communications with EM GA and GC GC communications are routed through the radios on the EM while communications with the EM and GA are handled internally within the HRV 41 Motors Motor Controller Data Power system Force Torque Data Sensors Breaker Reset Joint postion Power system health data Reset commands Joint postion thermocouple input F T data temperature data Power commands which devices are on off 4 7 motor power up heater on off commands To Vision System motor commands to stop imminent collision commands and data from ground and vice versa commands from ground and temp data from DR Interface with all modules power data and telemetry and GC commands collision data and corrective actions proximity data To Vision System comm link data S comm link data comm link 55 IRED Sensor GA Gc Data Figure 6 6 Level 1 Main Control 42 6 4 3 2 Level 1 Vision System Vision operating system The vision system requires a dedicated OS to help it manage the system resources and handle the deluge of data that must pass through the visions system s limited data bus bandwidth It also coordinates all the communication between each software module within the vision system LCS Controller Directly controls the LCS receives
71. do no damage to the HRV GA DR 3 do not prevent success of RSS mission The DR software shall be capable of operating all actuators and devices on the DR The DR software shall interface with the GA software such that it is capable of commanding the GA to move the DR to any desired position and orientation as well as halting such motion at any time The DR software shall complete machine vision processing tasks in a timely fashion such that it does not unduly prolong servicing operations The DR software shall be capable of accessing the communications system on the EM and communicating with ground control Requirements M K and L were eliminated from the top ten list as a result of this procedure 6 4 2 Level 0 Rationale Our overall software architecture consists of two distinct elements the main command module and the vision system module This division was chosen because each software element will reside on an independent processor and will be carrying out vastly different tasks with differing software and hardware requirements Taken together these modules interpret all sensory information provided by the data gathering systems on the DR and communicate the condition of the DR and its surroundings to the outside world GC EM GA etc This dual architecture is summarized is Figure 6 5 below 39 Force Torque Sensors Tool Caddy Touch Sensors Actuator Motor Controllers 15 bw
72. driven Operator error incorrect double check system input command command confirm then send Operator error accidental double positive system to send commands command GA DR DR releases Damage to movement w payload HST by payload 8 securely payload collides payload with HST Table 2 FMEA Detailed Analysis Mechanical failure wear on DR wil have a double grapple system 2 DR end effector payload slips independent means of gripping Structural failure overloaded Design DR to withstand loads greater than DR end effector fails the anticipated maximum Electrical failure no DR to enter safe mode when there is a communication between GC comunication failure ie movement ceases and DR and GA untill further instruction Sensor failure loss of DR to enter safe mode when there is a feedback sensor failure Command corruption DR implement a double positive system for incorrectly or inadvertantly release A single corrupt command cannot signalled to release have damaging effects Power failure end effector End effector normal state is closed reaqires opens electrical power to open Operator error incorrect double check system input command command to release confirm then send Operator error accidental double positive system to send commands command to release 92 Appendix 4 1 Frequency and Severity Ratings for FMEA Number Description za o Continuously
73. ertet 129 Appendix 7 2 5 EFBD 4 lt Tool Caddy te er dete te pes 130 Appendix 7 2 6 5 Tool Gripper 131 Appendix 7 2 7 EF BD 6 Clamp EU eee etre e euer sa hte edes aie 132 Appendix 7 2 8 EFBD 7 Vision Processor enne eene 133 Appendix 7 2 9 EFBD 8 CBU i sso e Renten e ege ee ete gap ea t eere 134 Appendix 7 2 10 9 Force Torque Sensor 135 Appendix 7 2 11 I0 Miri Camera eie eee e ee pei Foe e 135 APPENDIX 73 POWER DEMAND nen nennt ener nennen 136 APPENDIX 7 4 DR CABLE MASS 137 Appendix 7 4 1 Power Cables cssc cesses bh ewe ee tee eive de repa Ste d Weed a teasers 137 Appendix 7 4 2 Power Sample Calculations 136 Appendix 7 4 3 Data Cables iii aue Re ne nua edito uerbi ise eitis 139 Appendix 7 4 4 Data Sample Calculations eese eese ener nennen nennen rennes 140 APPENDIX 7 54 OA CABDEMASS iino gna nennen eat eo Ho tute e i a ee SeS 141 APPENDIX S MECHANICAL 142 APPENDIX 8 1 142 APPENDIX 8 2 RANGE OF MOTION SIMULATION cesses een ene een nnn nnne nnne 145 APPENDIX 83 00 146 Appendix 8 3 1 Tool Manipulator Arm Calculations 146 Appendix 8 3 2 Tool Manipulator Joints Calculations
74. for the cold case will be 16 22 W and 0 62 W for the hot case Hence we require a 20 W heating capacity It is favorable to have a duty ratio to supply the designed 20 W need A 30 W heater with a 67 duty ratio should be sufficient 160 Appendix 8 6 End Effector Performance Stopping Distances Global Stopping Distance 2 0 0508 m Stopping Angle 2 0 034907 rad Total Stopping Distance 0 01016 Bending Portion 0 002 m Effective Stopping Distance 0 00816 m Total Stopping Angle 0 006981 rad Portion Torsion Portion 0 000175 Effective Stopping Angle 0 006807 rad Resolution Configurations were chosen to be somewhat representative of arm configurations during operation as well as to explore the extremities of the operating envelope While this analysis is not exhaustive it is representative of the overall performance of the arm Joint Angle Error 4 Minutes 4 360 60 PI 180 radians 0 0000032321 radians 89 degrees was chosen instead of 90 to avoid singularities in inverse kinematics calculations The Maple code can be found on the following page Worst Resolution is the maximum of the absolute values of the various computed position errors Theta1 Theta2 Theta3 Theta4 Theta5 Theta DeitaX 0 0 00 1 3E 05 1 3 05 9 0 06 99 06 4 4 06 DeitaY 1 8E 06 136 05 7 0 08 3 6E 07 52 06 3 0E 06 24 06 1 7E 08 Deitaz 2 5 05 7 5E 07 22
75. from the sun that reaches the detector that could possibly create any interference in the measurement As say the immunity has been proven several times as well gt 1 Since the LCS determines depth information by bouncing a laser off gt of an object how well does it perform on a highly specular surface gt such as the Hubble the exterior is as shiny as a mirror Excellent question Two questions 1 As with any optical system specular surfaces pose a difficulty Keep in mind that surfaces might be specular at one wavelength of light but not another don t know the specular reflectivity of Hubble for near IR like 1500 nm Of course don t know it for visible light either The net effect of specular surfaces is that we can only see parts where 110 the surface normal is generally pointing back towards the camera plus or minus some angle We ve scanned many specular surfaces successfully including in space but in areas where the normal is steep relative to the camera we don t get any measurement Again that s true of any optical system gt 2 know the LCS has two modes operation scanning and tracking gt could you elaborate on the advantages and limitations of either mode gt Does tracking require pre placed targets or will well defined edges gt suffice Things have changed a little In the original software these were the only modes Scanning could be done on anything It entailed moving the laser s
76. g 2x1024 For other scan patterns the resolution is anywhere from 2 to 1024 points in the scan pattern The FOV that the raster images or scan patterns is completely adjustable so you can make 1024x1024 points cover 30deg x 30deg or as low as Odeg x Odeg measuring the same point a million times So there is a wide range of possible scanning configurations As far as a 3D model we have software that tracks objects and updates the pose estimation with a 3D model of the object Autonomous rendezvous and docking is one of the applications we are looking at using this for but there are a number of other applications We tend to use non raster patterns for this since we don t need all of that data to get the pose estimation gt 4 How large Mb is each scan are you aware of any rad hard gt processors that can deal with that much information to provide useful gt feedback for a control loop our robotic arms Yes we are working on some of that already with our current NASA contract As far as the processor don t have the exact answer We have ones that are rad hard but don t know the models can find out later but it will be tomorrow think the board is one possibility can t remember the manufacturer The scans are about 10 bytes per voxel measurement About 10 MB for a 1024x1024 But that s before compression 5 Has NepTec used the LCS to provide visual feedback to a control gt system how did you do thi
77. iron loss due to hysteresis and eddy currents and the mechanical loss due to windage and friction Applications Brushless dc motors are widely used in various applications Two examples of them are illustrated in the following Or Tload Tlosses Tem Fig 13 curve of a brushless dc motor with a constant voltage supply Page 12 9 48531 EMS Chapter 12 Brushless DC Motors Laser printer In a laser printer a polygon mirror is coupled directly to the motor shaft and its speed is controlled very accurately in the range from 5000 to 40 000 rpm When an intensity modulated laser beam strikes the revolving polygon mirror the reflected beam travels in different direction according to the position of the rotor at that moment Therefore this reflected beam can be used for scanning as shown in Fig 14 How an image is produced is explained using Fig 15 and the following statements 1 The drum has a photoconductive layer e g Cds on its surface with photosensitivity of the layer being tuned to the wavelength of the laser The latent image of the information to be printed formed on the drum surface by the laser and then developed by the attracted toner 2 The developed image is then transferred to normal paper and fixed using heat and pressure 3 The latent image is eliminated A recent brushless dc motor designed for a laser printer is shown in Fig 16 and its characteristic data are given in Table 2
78. is both appropriate and feasible for the DR 5 7 2 5 Main CPU Telemetry Reporting The Main CPU will report telemetry to ground control whenever the DR is in an operating mode This process will take place continuously without being initiated by controllers since we desire continuous data collection The CPU will initiate commands to the EM communications system when it needs to transmit data The separation of telemetry transmission from central robot functions means that telemetry signals could be displaced from the communication bus in the event of higher priority signals This could lead to loss of telemetry at times but can be mitigated by appropriate use of interrupt priorities and scheduling rules 5 7 2 6 Collision Detection System Emergency Stop The collision controller will continuously monitor the space available around the DR structure and halt operations when a collision is about to occur It does not receive any commands from other systems on the DR or from ground controllers The moment of approaching any physical object beyond the safety limit that collision sensors detect should cause the collision controller to automatically send the halt command to DR CPU This will trigger the Main CPU to stop any motor commands put the DR into safe mode and to signal the GA via the dedicated emergency stop communication bus Upon stopping the DR shall report its status to ground control and wait in safe mode for operators to asses
79. its displacement relative to its expected location and produce a delta vector that allows it to correct motions in real time Details of how this capability improves the performance of the DR is found in Section 6 Control System below 5 7 2 4 Main CPU Active Force Control AFC At its the primitive manual level of DR operators inputting commands at less than real time are unlikely to have great success preventing jamming while moving the WFC3 along the constrained path of the rails This problem is likely to be exacerbated by motion of the DR and GA as loads are applied The backup manual mode would achieve path following by monitoring forces and stopping the DR if load limits are exceeded However this requires GC to reassess and re plan the motion many times during the operation 25 We have decided to enhance the DR s autonomous capability so that it can to modify the joint torques in real time during the insertion motion This will improve the DR performance during WEC operations considerably by allowing it to correct for misalignment during insertion before jamming occurs This capability will require additional computational power on the Main CPU as well as data from force torque sensors placed at each end effector However we believe that this is achievable since AFC has been used on other robots most notably the SPDM as well as being used in robotic manufacturing 7 and surgery 8 For this reason we felt this technology
80. life of the DR DR GC To GA GC Readiness to grapple prior to un stowing Readiness to be moved away from open stow fixtures Desired position and orientation to which the GA should move the DR Envelope and mass of the DR and any payload prior being moved Resolution of Emergency Stop condition Readiness to be placed in open stow fixtures e Readiness to un grapple after stowing Ready to power off From GA GC e Successful grapple of DR Successful mating of connectors on DR GF Ready to power on Resolution of Emergency Stop condition Arrival at requested location Successful un grapple and de mating of connectors on DR GF 5 6 3 Personnel Needs The GA and DR are both mainly autonomous systems however human interaction with the robotic manipulators is required at many points in during the mission First a team will be required to prepare the GA and DR for launch performing manual safety and operational checkouts and finally stowing the robots on the HRV This group should have a broad technical skill set for the installation Also these persons should have a thorough understanding of the procedures to be performed during the mission in order to effectively test the robotic arms 22 During the mission from launch to the EM Jettison a team will work from the ground to direct the phase transitions of the GA and DR as well as to initiate robotic sequences This team is also responsible for manually operating the arms in the case o
81. matrix 3 3 cos x sin x 0 sin x cos x 0 0 0 1 Cit x matrix 3 3 1 0 0 0 cos x sin x 0 sin x cos x C2t x matrix 3 3 cos x 0 sin x 0 1 0 sin x 0 cos x C3t x matrix 3 3 cos x sin x 0 sin x cos x 0 0 0 1 11 matrix 3 1 0 15 0 0 12 2matrix 3 1 0 85 0 0 13 3 1 0 85 0 0 14 3 1 0 15 0 0 15 3 1 0 15 0 0 16 3 1 0 15 0 0 finding xyz in terms of the joint angles x6 evalm 16 x5 evalm multiply C1t theta6 x6 15 x4 evalm multiply theta5S 5 14 x3 evalm multiply C2t theta4 x4 13 x2 evalm multiply C2t theta3 x3 12 x1 evalm multiply C2t theta2 x2 11 xsol evalm multiply Clt thetal x1 X1 xsol 1 1 X2 xsol 2 1 X3 xsol 3 1 multiply C1 theta6 C3 theta5 C2 theta4 C2 theta3 C2 theta2 C1 theta A general rotation matrix used in order to find orientation of EE wrt base Cgeneral multiply C3t beta3 C2t beta2 C1t betal sols 2 solve sin beta2 Cbig 3 1 beta2 53 solve cos sols 2 sc Cbig 2 1 sc 51 solve sa cos sols 2 Cbig 3 2 sa 1 solve cos sols 2 ca Cbig 3 3 ca C3 solve cc cos sols 2 Cbig 1 1 sols 1 arctan S1 C1l sols 3 arctan S3 C3 Solve for Jacobian Xv vector X1 X2 X3 sols 1 sols 2 sols 3 thetav vector thetal theta2 theta3 theta4 theta5 theta6
82. maximum level of redundancy with appropriate factors of safety HST level 1 performance is preserved by the hazard mitigation strategy of stopping the GA and DR as soon as fault conditions are detected and having ground controllers assess such situations for safety Finally the DR meets all the requirements given by the customer and is the best solution to the given problem In short the DR Rocks Table of Contents ACKNOWLEDGEMENTS ses sscssassesecesepescnsvincscavaeaexnsdunsorsnsvenecielstnssecatnivsuedaunarsnesedecsessaecsuesuepvecesoavenessessens II EXECUTIVE SUMMARY REESE LEER YE US ER AERE NER ERR TABLE OF CONTENTS IV THIS PAGE INTENTIONALLY LEFT 01 9411617 1 2 lt lt 3 3 1 MISSION SCOPE 3 3 2 MISSION OBJECTIVES enim Eo HER DERI TEUER 3 324 Power Augmentation sie tee D eH GR ene eee eese cedere eiae ten 3 3 2 2 Replace aging Rate Sensing Units RSUS 3 3 23 Extend Scientifie Life esci e e EFRON eu ee P e Pe ep POE ERE PME 3 324 DONG Harm io Hubble t
83. model matching or registration this is the gt one that we re really struggling with since we need to select a gt processor that s up to the task Ooh tough question We tend not to calculate it We just do it and see how long it takes Currently our 3D model pose estimation calculations registration is on the order of a few milliseconds on a 3 GHz PC But we re using some proprietary algos Other algos can take many seconds to minutes to register data It really depends on the algos gt well that about sums it up gt gt really appreciate your help OK Hope this all helps 113 11 7 DataDictionary Device Data Description To From Units Range Precision The three dimentional map LCS 16777216 4096x LCS 3D map of the CPU LCS N A 30 bits 4096 Workspace per image resolution and surrounding 0 1mm 1m LCS 2mm 5m Distance LCS m 30m 13 bits 10mm CPU 10m 80mm 30m 659 H x Minicams 4 Video 0000 494 control infinite whether the Camera Lighting a state lights have N A 0 1 1 bit 1 System to be on or off indicates whether they too DR IR IR Sensors on off close to the CPU Sensors N A 0 1 1 bit 1 Hubble for collision motor shaft Resolvers 16 motor position ae to DR RESPINS arc sec 0 7 20 bits 224 520 P CPU 16 135 mins position Torque at T F Sensors 2 Torque motor shaft N m of EE Force at Force mo
84. mostly cabling the GA and computers in the EM are relatively small and will be given a more thorough examination in a more detailed design That said however the cabling mass present in the GA due to DR needs has been communicated to the GA team for inclusion into their mass budget 8 6 Design Tradeoffs 8 6 1 Joints 8 6 1 1 Varying Joints vs Standardized Having all joints the same size was considered but rejected as it is not a mission requirement to be able to change out a joint nor is it realistic for the robot to achieve that level of self reparability Since the driving reason for uniform joint size would be to make spares interchangeable there is no reason for the DR joints to be uniform in size Diminishing joint strengths were selected as this allows for an overall reduction of mass along the arm and thus reduces the loads on the joints and booms 8 6 1 2 Titanium vs Aluminum Titanium has a CTE much closer to Steel than Aluminum and so a joint housing made from titanium will have much lower thermal stresses between the housing steel bearings shafts gears within the motor By keeping thermal stresses small it is expected that the friction to drive the joints will be kept at a reasonable level well within the loads specified for the motors Material CTE 2 Steel 12 6 um m C Aluminum 24 um m C Titanium 8 7 um m C 8 6 1 3 Single Axis Motors vs Tendons Since precision stiffness and controllability is the dri
85. motor 4 Temperature to ensure minimum survival temperature is maintained 29 Human operators at ground control will command the dexterous robot However several subsystems on the dexterous robot and the GA which interfaces with the DR are capable of autonomous actions and thus are capable of influencing the DR independently of Ground Control This section lists these actors and describes their autonomous functionality 6 2 3 Controller Overview 6 2 3 1 Arm Motor Control The absolute coordinate system will be as follows The z axis is along the cylindrical axis of HST the x axis is orthogonal to the z axis along the length of the solar array boom and the y axis is orthogonal to both axes This coordinate system has been chosen to be on HST since this way we can pre determine the required positions of the workspace from the Hubble model available The ground controllers are going to be in control of the ultimate position of the end effector From the LCS feedback GC can locate the end effectors as well as identifiable features on the Hubble From this data the ground control computer will calculate the relative position and orientation of the end effectors Using the existing 3D model of Hubble GC will calculate the position of the end effector relative to the fixed coordinate system mentioned above This way GC is going to be aware of the exact location and orientation of the end effector relative to the fixed coordinate system
86. requirements system architecture system block diagram showing the top level components of our system physical architecture and the summarized power and mass budgets 4 1 Top Level Requirements The top level requirements were derived from the RFP and these were broken down further to get the system requirements on which our DR design was derived The sections that follow present these requirements and the top level system architecture designed to satisfy these requirements followed by a system block diagram that outlines these systems 4 1 1 Functional Requirements The DR shall be able to perform the following operations DR F1 Power augmentation DR F1 1 Tap SA3 power at P6A and P8A on both HST diode boxes DR F1 2 Rout SA3 power to DM via new harness DR F1 3 Harness Attachments 12 locations to hold down conduit DR 2 WFC3 installation DR F2 1 Attach new ground strap stowage fixture DR F2 2 WF PC2 Interface plate DR F2 3 WF PC 2 blind mate release DR F2 4 Release and secure Ground strap DR F2 5 Release A latch DR F2 6 Remove and stow WF PC2 DR F2 7 Retrieve and position WFC3 DR F2 8 Install WFC3 into telescope DR F2 9 Replace latch A DR F2 10 Replace ground strap DR F2 11 Replace blind mate DR F2 12Final stow WF PC2 DR F3 Gyro data and power augmentation DR F3 1 486 1553 data bus installation J9 connector on HST bay 1 DR F3 2 Power for Gyros supplied by harness from DM to WFC3 DR F4 All the above functions hav
87. resulting in near zero noise distortion TYPICAL APPLICATIONS Rehabilitation research Robotic assembly Orthopedic research Product testing Telerobotics Fz 0 500 Tx Ty in Ib 1000 Tz in lb Fx Fy Ib Fz Ib Tx Ty in Ib Tz in Ib Fx Fy N Fz N 2500 3750 6250 Tx Ty 120 240 400 Tz N m Fz N 1 16 Tx Ty N m 1 10 1 160 Tz N m 1 20 1 320 Contact ATI for complex loading information Resolutions are typical Controller F T System DAQ 16 bit DAQ F T System 22 ATI INDUSTRIAL AUTOMATION DESCIOFTION INTIATOR 02 Release MOUNTING ADAPTOR PLATE 03 Removed and Aluminum from Note 1 LJH 9230 05 1076 CUSTOMER MACHINES MOUNTING PATTERN AS NEEDED IN PLATE REMOVE PLATE PRIOR TO MACHINING 4 12 1 75 12 DEEP SEE NOTE 4 100 B C EQUALLY SPACED 9100015 iso u7 nr 12 DEEP SEE NOTE 4 0 0025 ISO H7 FIT 9 8 DEEP SEE NOTE 4 TOOL SIDE MOUNTING SIDE ISOMETRIC VIEW NOTTS UNITSS OTHFRWISF 5 DO NOI SCALE DRAWING DRAWN IN SOLIDWORKS ALL DIMENSIONS ARE IN MILLIMETERS NOTES 1 Material Hardened stainless steel 2 Sensing reference frame origin at surface center of tool adaptor 3 Do No
88. site on the side of the EM and position itself to grapple the exposed DR Grapple Fixture GF To simplify the operation we designed the GF on the Figure 5 1 DR is stowed face down DR to emulate a standard FRGF like those on the HST and with GF exposed for easy access positioned it so that it is exposed and easy to reach 16 The DR will be a passive target during this phase as its primary systems will be un powered until the GA has made the power and data connection DR ground control will await confirmation of successful structural and connector mating and will then activate the main power and data systems of the DR This will supply power to the robotic part of the DR via busses running along the GA Once the DR has been activated and tested the stow fixtures will release and the GA will move the DR clear of the EM for final testing 5 3 2 DR repositioning during servicing During servicing operations the DR will need to be moved from work site to work site by the GA The DR has an arm span of about 4 8 m 2 4 meter arms so it is capable of reaching all necessary parts of a given work site while executing servicing tasks However the servicing operations take place at various sites necessitating DR mobility Combined motion will be accomplished by the series of operations described in the second Combined GA DR Move Command and Control Flow Down diagram in Appendix 2 In essence the DR will assume a static configur
89. sufficiently stable such that it does not crash or malfunction during servicing operations h The DR software shall have a situational awareness model that incorporates data from DR sensors ie motor encoders the DR vision system and internally stored data self knowledge i The DR software shall interface with the GA software such that it is capable of commanding the GA to move the DR to any desired position and orientation as well as halting such motion at any time j The DR software shall have a minimum level of autonomy such that it is able to detect a collision and take appropriate actions to prevent the following in order of priority 1 do no damage to the HST 2 do no damage to the HRV GA DR 3 do not prevent success of RSS mission 37 k The DR software shall be capable of a self assessment to ensure to the integrity of its executables 1 The DR software shall be capable of downloading patches and bug fixes via the GC comm system to correct errors in its programming m The DR software shall be capable of interfacing with the HST system via the EM comm system such that it can trigger internal mechanisms of the HST such as the detector vent valves Ranking these in terms of their respective core functionality generates the following b a c g d e i h j m f k Ranking in terms of complexity h c j f e d 1 g 1 m b a k This produces the following matrix complexity functional
90. the DR is 340 kg 4 4 System Conclusion The HRV mission presents several engineering challenges On orbit robotic servicing will require significant improvements in control communications imaging systems and machine vision While NASA has requested that the HRV not be an R amp D project it is apparent that some new technologies like the LCS are needed in order to carry out the mission We had to consider technologies that have not been verified for use in space This is especially important given that NASA needs to have the HRV in a timely fashion and in a form that it is reliable enough to service the one of the most valuable space assets in orbit 13 5 Operations This section describes the operations and procedures followed by the DR and its controllers in carrying out the mission tasks identified in section 3 above Hazard mitigation and system autonomy are also discussed 5 1 Operational Overview 5 1 1 Operational Policies In order to maximize the likelihood of the success of the primary and secondary mission objectives the DR is required to have limited single fault tolerance We designed the functional flow of the mission to accommodate appropriate fail safes redundancies and contingency scenarios It is paramount that the DR does not degrade the Level 1 performance of Hubble during servicing operations Appropriate control precision reliability safe modes and abort scenarios were therefore designed Additionally we de
91. the Halt Sleep bit instruction EM6607 in SLEEP mode The oscillator stops and most write functions of the EM6607 are inactive To be able to write the SLEEP bit the SL mask bit must be first set to 1 in IRQ register WD In SLEEP mode only the voltage regulator and RESET input are active The RAM data integrity is maintained SLEEP mode may be cancelled only by a Reset 1 RESET the terminal pin of the EM6607 by the v selected port A input reset combination This combination is a metal option see paragraph 15 1 2 The RESET port Reset 1 Figure 5 Mode Transition Diagram Reset 1 must be high for at least 10 Due to the cold start characteristics of the oscillator waking up from SLEEP mode may take some time to guarantee that the oscillator has started correctly During this time the circuit is in RESET state and the strobe output STB RST is high Waking up from SLEEP mode clears the SLEEP flag but not the SLmask bit By reading SLmask it can therefore determine if the EM6607 was powered up SLmask 0 or woken from SLEEP mode SLmask 1 Table 1 IntRq register Bit __ Name_ sd Reset_ R W Description INTPR 0 Prescaler interrupt request INTTE 0 X Timer counter interrupt request INTPC 0 R Port Interrupt request 0 0 Port Interrupt request SLEEP 0 1 1 W SLEEP mode flag Write bit 2 only if SLmask 1 06 04 Rev B
92. the clip in place The springs have to be designed such that when the clip is closed all the way in the tightest position the springs are still in compression An appropriate force that the clamp should withstand in the most closed position while the springs are in compression is about 10 N In the clip design the distance between the pivot and the springs is a quarter of the distance from the pivot to the clip end This means that when balancing moments the springs should provide a force of 4 x 1 4 lb ft in tension To have this tension force in a relatively small tensile displacement for the springs such as 0 5 inch we need an effective spring constant to be f x 4 0 5 8 Ib ft inch 1400 N m Two springs each with the above spring constant are included for redundancy The spring will be directly welded to the titanium clip The clip should be made from titantum to have them as light as possible because we will have 24 of them as seen below Harnesses needed Number needed Conduit 12 Diodebox connectors 8 Ground strap 1 Conservative addition 3 Total 24 Table 8 5 Clip tools 8 3 5 Tool Caddy The tool caddy consists of 2 rails holding the multipurpose clips and a center console designed to house the remaining tools Pressure sensors will be located at the base of each tool inset to ensure proper removal and storage The tool interfaces protrude from the body of the DR to 66
93. to be desirable and trades on system autonomy are viewed with the aim of minimizing the number of actors that require level 3 autonomy Appendix 5 2 Command and Control Flow Down These diagrams are made to illustrate the level of autonomy involved in each operational process and mission task executed by the DR For a definition of the various levels of autonomy see Appendix 5 1 above The reader should gain an understanding of which subsystems use low level continuous loops or closed loop control and which systems require a level of self control that is compatible with the conventional definition of autonomy Additionally these diagrams identify the initiators of each operation and trance how commands and control of the DR passes through the system 94 Teonuepi rpepueuiuios suor uaaq seu Anawaja aey pue uor poday 519103009 JOJO 5 pue 507 40 deu Qe wersja peej un JOSS JOld 5 5 UOISIA 10 Siosues 04 payeulps00g andwog wa s s 20 auigJj pue 652119 dew peej mey un pea 10 SIOSUAS pauinbas ajndwog uogensibay nauieja O sv B i
94. to its stow location for deorbit it is not necessary to reconnect the electrical interface as the DR is no longer needed Drawings detailing the stow configuration can be found in Appendix 6 2 2 3 Capture Envelope The capture envelope for the GF is defined in Figure 14 4 2 1 in the FRGF document reproduced in Appendix 6 3 This envelope ensures firstly that the EE is moving at correct speeds during the approach to the GF and secondly that it is in the correct position to reduce the chances for damage to either the EE or the DR The DR stowage configuration accommodates this capture envelope since the GF is positioned away from any other components on the EM and nothing on the spacecraft interferes with the capture envelope 2 4 Loading The dominant interface force is 355 N and results from applying 50ft Ib of torque at the DR end effector The dominant torque is 445 Nm and results from stopping 1000Ib mass Note that these numbers include a factor of safety of 1 75 The interface will have the necessary stiffness and strength to withstand these loads The details of these calculations can be found in Appendix 6 4 The DR also imposes a cable load requirement on the GA requiring 3 4 kg of cabling and associated accessories to be routed through the GA This imposes structural requirements as well as adding to the force required from each of the motors Using the estimation that a 100 wire bundle requires 5 Nm of torque we have 3 2 Nm neede
95. without recalibration The DR grapple fixture will be located on the side of the main body This will be the most accessible location on the DR while it is in its stowed position therefore facilitating the initial capture of the DR by the GA The GF will have the same basic structure as the FRGF with some additions First the GF will include two electrical ports to provide power and data connection to link the DR to its support systems in the EM through wires in the GA Corresponding ports will be placed on the EE and both will be located on the outside of the GF and EE at 60 and 180 from the primary target Second the EE cannot rotate to use its backup camera in the event of failure since the ports must align to its corresponding port on the DR Thus the DR grapple fixture will have two targets orientated 120 from each other and if needed the backup camera will use the backup target for capture Both the mechanical and electrical connections will be simultaneously made during capture This requires high accuracy in rotation when the EE contacts with the GF back plate so that the electrical ports mate properly The rotational accuracy is provided by teeth that are recessed away from the EE shown in Appendix 6 1 1 and 6 1 2 A detail of the teeth is shown in Appendix 6 1 3 These teeth match opposing teeth on the DR GF and align the EE to within the position tolerance of the electrical port The teeth are recessed so they do not damage the HST
96. 00 FAX 1 858 503 3301 EMAIL info maxwell com Doc Rev 4 Page 5 of 5 SCS750A MICROELECTRONICS WE TECHNOLOGIES ENGEL Planetary Gearheads 92 9 b in Motor and Gearhead combinations GP48 2 fits motor series GNM2636A amp GNM2670A Series 6482000 GP48 2 GP48 2 Housing material metal Backlash at no load lt 2 0 Shaft load max radial Ibs 40 5 axial Ibs 33 8 Series GP48 2 with Motor Series GNM 2670A length output torque reduction ratio weight with continuous intermittent direction efficiency without motor operation operation of rotation motor GNM 2670A M max Mmax M max M max reversible Kg oz mm in Nm Ib in Nm Ib in 96 5 1 0 37 13 1 198 7 80 1 8 85 3 26 6 90 6 1 0 37 13 1 198 7 80 1 3 11 5 3 5 31 0 E 90 7 66 1 0 37 13 1 198 7 80 1 8 85 3 26 6 90 21 1 0 56 19 8 214 5 8 44 3 2 28 3 12 106 2 85 25 1 0 56 19 8 214 5 8 44 4 35 4 14 5 128 3 85 30 1 0 56 19 8 214 5 8 44 4 8 42 5 14 5 128 3 85 36 1 0 56 19 8 214 5 8 44 5 5 48 7 16 141 6 85 46 1 0 56 19 8 214 5 8 44 5 6 49 6 16 141 6 85 59 1 0 56 19 8 214 5 8 44 6 53 1 16 141 6 85 94 1 0 74 26 1 231 5 9 11 7 5 66 4 18 159 3 80 125 1 0 74 26 1 231 5 9 11 8 5 75 2 20 177 0 80 150 1 0 74 26 1 231 5 9 11 9 79 7 20 177 0 80 Series GP48 2 with Motor Series GNM 2636A engt output torque reduction ratio weight with continuous intermittent direction efficiency
97. 1 811 30 1 Front View MicroMo Electronics Inc 14881 Evergreen Avenue Clearwater FL 33762 3008 Toll Free 800 807 9166 Fax 727 573 5918 info micromo com www micromo com For notes on technical data refer to Technical Information Specifications subject to change without notice MME0604 BAE SYSTEMS rad hard SRAMs are being used in a variety of important programs for NASA defense and commercial satellite applications The 1M SRAMs offer 25 30 and 40ns access times in our proven epitaxial bulk 0 5 micrometer process With total dose hardness greater than 1x10 rad Si dose rate upset of greater than BAE SYSTEMS in Manassas Virginia with more than 17 years of experience supporting our space customers offers a wide range of radiation hardened static random access memory M A SRAM devices produced on our line qualified by the Defense Department s rigorous Qualified Manufacturer Listing QML program Our radiation hardened SRAMs range from 64K to 4M in density All are built in epitaxial bulk complementary metal oxide semiconductor CMOS processes in our QML qualified 1 0 micrometer 0 8 micrometer and 0 5 micrometer technologies We also offer parts that operate with 2 5 3 3 and 5 0 Volt power supplies To meet special customer needs our radiation hardened multi chip packaging technology is also available for high performance high reliability space applicatio
98. 1 3 50 7 081 130 18 410 55 Series G6 1 with Motor Series GNM 5480 engt output torque reduction ratio weight with continuous intermittent direction efficiency without motor operation operation of rotation motor GNM 5480 M max M max max reversible Kg 02 mm in Nm oz in Nm oz in 8 1 2 30 81 1 290 11 42 5 8 821 36 5 098 85 16 8 1 2 90 102 314 12 36 11 1 558 70 9 913 70 23 2 1 2 90 102 314 12 36 15 2 124 92 13 028 70 32 8 1 2 90 102 314 12 36 21 2 974 125 17 702 70 45 3 1 2 90 102 314 12 36 29 4 107 130 18 410 70 68 9 1 3 20 113 327 12 87 39 5 523 130 18 140 55 95 1 1 3 20 113 327 12 87 50 7 081 130 18 410 55 134 5 1 3 20 113 327 12 87 50 7 081 130 18 410 55 MicroMo Electronics Inc 14881 Evergreen Avenue Clearwater FL 33762 3008 Toll Free 800 807 9166 Fax 727 573 5918 info micromo com gt www micromo com For notes on technical data refer to Technical Information Specifications subject to change without notice MME0402 ENGEL M6 12 472 DEEP KEY DIN 6885 6x6x28 20 Po 787 000 T g P i 083 084 0163 236 32 330 3 gps 787 35 138 085 138 3 346 28 4 bes 1 102 157 157 zog 197 BS L 1 102 44 1 732 GNM 54 G6 1 MODEL RATIO DIMENSIONS mm in 5440 13451 1
99. 2 02 95 2 3 75 93 2 3 67 108 6 4 28 109 6 4 31 116 6 4 59 40 40 53 53 60 21 8 3 59 2 2 33 103 2 4 06 101 2 3 98 116 6 4 59 117 6 4 63 124 6 4 91 40 40 53 53 55 592 1 8 8 59 2 2 33 103 2 4 06 101 2 3 98 116 6 4 59 117 6 4 63 124 6 4 91 40 40 53 53 55 989 1 8 8 59 2 2 33 103 2 4 06 101 2 3 98 116 6 4 59 117 6 4 63 124 6 4 91 40 40 53 53 E 55 1526 1 8 8 59 2 2 33 103 2 4 06 101 2 3 98 116 6 4 59 117 6 4 63 124 6 4 91 40 40 53 53 55 Gearheads with ratio 14 1 have plastic gears in the input stage For extended life performance the gearheads are available with all steel gears and heavy duty lubricant as type 30 1 S add 1 4 mm 0 055 in to L2 column to account for larger mounting flange The values for the torque rating indicated in parenthesis are for gearheads type 30 1 S with all steel gears Note Reduction ratios have been rounded off Exact values are available upon request 2338 30 3056 4x M3 23 2342 928 2842 1 181 4 157 DEEP 906 1 102 418 0 018 3564 Orientation with 24 2444 930 3042 709 35 3557 respect to motor 945 1 181 p 0 008 1 378 terminals not defined 1 181 98 0 017 315 E rl 276 i 1 1 1o 1 024 NE d 1 1 024 657 10 394 12 03 12 0 5 i L1 0 8 20 6 0 3 11 0 8 30
100. 22 000 rpm thermal resistance R 55 reduced n rpm 35000 30000 ne max 27000 rpm E 25000 n 22000 rpm ed 20000 o 15000 Me max 6 67 oz in 10000 5000 M oz in 40 50 60 70 80 Torque oz in Recommended area for continuous operation MicroMo Electronics Inc 14881 Evergreen Avenue Clearwater FL 33762 3008 Toll Free 800 807 9166 Fax 727 573 5918 info micromo com gt www micromo com For notes on technical data refer to Technical Information Specifications subject to change without notice MME0404 FAULHABER Option K1000 Motors in autoclavable version K1155 Motors for operation with Series 3564 B Motion Controller MCBL 2085 3564 QE 0 40 003 035 01 B16 o oos 0 002 1 378 630 90 05 A N 8 102 12 6 0 3 496 64 14 03 551 3564 20 Front View 0 0 003 016 04 0002 016 008 157 20 05 10 02 496 14 7 12 6 10 3 055 20 9 96 03 65 8 14 03 I 022 823 378 2 591 3564 312 551 866 Cable and connection information gt Cable Single wires material PTFE Length 300 mm x 15 mm 11 8 0 6 in 3 conductors 20 AWG 5 conductors 26 AWG Connection A Hall sensor green A Phase brown B Hall sensor blue
101. 4 TEST AT EM ACTIVE SUPPLY CURRENT TEST30 15 METAL MASK OPTIONS 15 1 1 Power Check Level Option 15 1 2 PortA reset Option see paragraph 3 3 15 1 3 SVLD levels Option see paragraph 10 0 SVLD 16 PERIPHERAL MEMORY MAP 26 28 29 30 17 TEMPERATURE AND VOLTAGE BEHAVIOURS 36 17 1 IDD CURRENT TYPICAL 17 2 PULL DOWN RESISTANCE TYPICAL 17 3 OUTPUT CURRENTS TYPICAL 18 ELECTRICAL SPECIFICATIONS 18 1 ABSOLUTE MAXIMUM RATINGS 18 2 STANDARD OPERATING CONDITIONS 18 3 HANDLING PROCEDURES 18 4 DC CHARACTERISTICS POWER SUPPLY PINS 18 5 DC CHARACTERISTICS INPUT OuTPUT PINS 36 37 38 40 40 40 40 40 42 EM6607 18 6 DC CHARACTERISTICS SUPPLY VOLTAGE DETECTOR LEVELS 18 7 OSCILLATOR 18 8 INPUT TIMING CHARACTERISTICS 19 PAD LOCATION DIAGRAM 20 PACKAGE DIMENSIONS 21 ORDERING INFORMATION 21 1 PACKAGE MARKING 21 2 CUSTOMER MARKING Table of Figures Figure 1 Figure 2 Figure 3 Figure 4 Figure 5 Figure 6 Figure 7 Figure 8 Figure 9 Figure 10 Figure 11 Figure 12 Figure 13 Figure 14 Figure 15 Figure 16 Figure 17 Figure 18 Figure 19 Figure 20 Architecture Pin Configuration Typical Configuration Voo 1 4V up to 3 3V Typical Configuration Vpp 1 2V up to 1 8V Mode Transition Diagram System reset generation Port A Port B Port C Port D Port E Timer Event Counter Interrupt Request generation Serial write buffer Automatic Serial Write Buffer transmission Int
102. 5 123 LI A A Ae Ew d o 49 S amp S gt gt gt To Layout and 22229 29 8888688 Cabling 6 2 m 4 M Efe 8s s 2 ge 44535 53595 1 m m i s o 1 2 f 4 22 1 554 Lage 2 i a i 22 hd 9 p gs L p aa lt 9 32 23 oge P 5 9 0 e 55 2 ESTS 5 M M 3888 a 9 sna ES ama E lt LCS Unit p 772 2 ole oe ee 6961 vea sna gt lt xv I L wova sn Hl Connector 2 All Backup Power Busses PxB 20 Pins Bundle 2 I d e ME E 9 s 5 _ Tek qoe 4 8 Eu z 3 lls l J ALL Le gl d 2555 B BES RRR I WR Uu 2 44 x m M M d lt EB 22505 s o 9 5 g To Layout and 2 a 259 5 5 Cabling 6 B au n 428488 abling Appendix 7 1 6 Layout a
103. 5 9000 06 06 41 9 13500 WristYaw 1356 124 150 35 9000 06 06 41 9 13500 Wrist Roll 1356 124 150 35 9000 06 06 41 9 13500 TodGiper 90 1 amp Gripper 90 1 LCS Pith o wd hip p Jr Yaw 500 Manipulator Arm Shoulder Roll 40 0 542 50 35 2500 0 6 06 44 4 12500 Shoulder Pitch 400 542 50 35 250 0 6 06 44 4 12500 Elbow Pitch 400 322 50 35 2500 0 6 06 444 12500 Wrist Pitch 400 100 50 35 2500 O6 06 44 4 12500 Wrist Yaw 400 100 50 35 2500 0 6 06 44 4 12500 Wrist Roll 400 100 50 35 250 O6 06 44 4 12500 Gripper OT J 152 EbowPidh 2250 99 35660248 20 1 12 Wrist Pich 2250 99 3567 0248 2011 12 Wrist Yaw 2950 99 35580248 20 1 12 Wrist Rol 2250 99 35590248 251 12 3w004B Gippe 3970481 LCS Pih T 1 D52948L ww breos Manipulator Am Wrist ich 2083 97 35 5024B 20 1 12 Wrist Yaw 293 97 35 6024B 20 1 12 Gipe 159080487 Appendix 8 3 8 Motor Sample Calculations G26 36 417 30 4 G26 36 417 30 4 G26 36 260 30 4 G26 36 260 30 4 G26 36 260 30 4 G26 36 260 30 4 G27 37 260 30ff 628 38 250 30 f G26 36 69 30 G26 36 69 30 f 153
104. 53 7 4 2 Power Bus Redundancy Each of the busses is electrically isolated from each other such that any shorting between the two busses is completely avoided This will prevent the majority of single fault failure modes and comply with customer requirement of single fault tolerance whereby a single fault in one bus could potentially corrupt both busses and render the DR inoperative Unfortunately this electrically isolated redundancy requirement has significant ramifications for the overall system design There now has to be a doubling of most electronic components that represent a critical loss in performance should they fail All MEU s and SEU s shall contain two identical sets of components connected to their own power bus one serving as the backup of the other We now require that our motors have dual windings such that either bus can drive the motor without having to physically switch the power connections between the busses or requiring a complicated clutch to switch between independent motors 7 4 3 Data Bus Redundancy The data busses in the DR will be redundant in a similar fashion as the power busses Each hardware string will be connected to its data bus whether primary or backup and there will be no interconnections between the data busses on the external component level ie outside the CPU This will prevent most of single point failures and the interconnection at the CPU could be designed such that a failure is unlikely Giv
105. 5565593 66 9 8 9 RIED 19 5 6 1 Initiation of Mission Tasks Internal Interfaces eese eene nnne 21 5 6 2 External Interfaces enn 22 IV 5 6 3 dees 22 5 6 4 X Existing Support Environment esien eneen eee neie aeea eae e a aeae Eea at Ne aS EE saeara ie 23 5 7 imo pet ES 23 2 Autonomy Requirements o eee eh eee teer toe ee eee eene eere eee E 24 DL lt cAULONOMOUS ATORIOCIMTOX 25 5 8 OPERATIONS TRADEOBES 75 6 entities tbe n n e o rne P reni i C I eR Pe FO RE tS E et 26 CONTROL SYSTEM ect 28 6 1 CONTROL REQUIREMENTS de hee e de eet ent reve e eee etes 28 MEME MIMEE 26 6 2 Effector Position ACCUL ACY eer e REPRE UOI RE ORE D Pee 28 6 13 End Effector Position Resolution eese 28 6 1 4 Vision System Sensor 28 6 1 5 Time Domain 28 6 2 CONTROL ARCHITEGTURE nete cede erede re e edes 29 6 2 1 Control Philosophy Distributed controllers and Centralized Coordination cesses 29
106. 8 2 2 3 Stopping Distance The stopping distance requirement imposed on us is to stop within 2 inches and 2 degrees from the maximum tip velocity when manipulating 100016 mass The GA has a much longer structure and so we have agreed with them that they will take 80 of this stopping distance budget This leaves 0 4 inches and 0 4 degrees for the DR imposing a 288 Nm torque on the GA as discussed above in section 8 2 2 2 Load Transfer The calculations is shown in Appendix 8 6 8 2 2 4 Release The GA will release the DR on the EM exterior for stowing The mechanical force for mating and demating will be approximately 10 20 N which the GA can perform 8 2 3 DR EM Interface The DR will be stowed on the exterior of the EM during launch proximity and capture operations This location was chosen over an interior bay to simplify the removal and return of the DR Exterior stowage eliminates the need for doors to be manipulated simplifies the configuration of the DR and gives the GA a wider work area when grappling the DR In order to secure the DR to the EM clamps will be located on the EM and corresponding towel bars on the DR The GA will signal ground control when it has securely grappled the DR and the 58 stowage clamps will be opened by ground control Similarly when the GA has returned the DR to the stow location a signal will be sent and the clamps closed The stowed configuation is shown in Figure 8 2 Figure 8 2 Stowed Conf
107. 85 7 1 287 11 299 81 290 11 417 5480 1681 4531 314 12 362 689 134511 327 12 874 3 701 Front View MicroMo Electronics Inc 14881 Evergreen Avenue Clearwater FL 33762 3008 Toll Free 800 807 9166 Fax 727 573 5918 info micromo com gt www micromo com For notes on technical data refer to Technical Information Specifications subject to change without notice MME0402 MICROELECTRONICS SCS7 5 0A SUPER COMPUTER FOR SPACE SCS750P PROTOTYPE MODULE As shown uses commercial components Flight board conduction cooled with space qualified components The SCS750A single board computer is Maxwell s answer to the space industry s need for high performance computing and on board data processing while providing excellent reliability upset immunity One 1 upset every 300 years in a GEO Orbit Up to 1000X Performance of Current Space Processor Boards Highest Space Qualified Performance 1800 MIPS the spacecraft which requires a large amount of processing power Demonstrated Radiation Tolerance This next generation super computer will enable future satellite Silicon On Insulator 501 Processors designs to dramatically increase error free on board data Actel RTAX S Radiation Tolerant FPGAs processing mission planning and critical decision making RAD PAK amp RAD STAK Packaged Memories Triple Modular Redundant Processing
108. Alclad 7075 O Alclad 7075 O Component Wt Al 87 1 91 4 Cr 0 18 0 28 Cu 1 2 2 Fe Max 0 5 Material Notes Data points with the AA note have been provided by the Aluminum Association Inc and are NOT FOR DESIGN Component Wt Component Wt Mg 2 1 2 9 Si Max 0 4 Mn Max 0 3 Ti Max 0 2 Other each Max 0 05 Zn 5 1 6 1 Other total 0 15 Click here to view available vendors for this material Mechanical Properties Ultimate Tensile Strength Tensile Yield Strength Elongation at Break Modulus of Elasticity Shear Strength Processing Properties Annealing Temperature Solution Temperature Metric 221 MPa 96 5 MPa 17 71 7 GPa 152 MPa 413 English 32000 psi 14000 psi 17 10400 ksi 22000 psi 775 F 466 482 870 900 F Comments AA Typical AA Typical AA Typical 1 16 in 1 6 mm Thickness AA Typical Average of tension and compression Compression modulus is about 2 greater than tensile modulus http www gtsculpture com designwiki HomePage AA Typical Kapton is a thin semitransparent material with excellent Gielectric strength Kapton heaters are ideal for applica tions with space and weight limitations or where the heater will be exposed to vacuum oil or chemicals FEP intemal adhesive for use to 200 C UL component recognition available Suitable for vacuum environments NASA RP 1061 NASA approved materials for space
109. DR and are based upon expected motor and other power system loads These estimates could be refined further given our updated mass budget and our improved fully three dimensional performance analysis in an iterative procedure However given the time constraints on this project it was felt that our current estimates are sufficient for a design in the PDR stage 8 5 2 Boom Structure Fairings The links between the DR joints were assumed to be perfect hollow tubes with a circular cross section An appropriate thickness was calculated based on stiffness calculations with predicted load cases The mass of the booms was simply calculated from the density of the chosen material carbon composite and material volume of the boom These calculations are detailed in Appendix 8 3 8 5 3 Joint Structure Without a detailed design the mass of the joint structure was largely an educated guess We selected a mass that would be comparable in that such a mass would be likely be able to accommodate the load cases A large margin ratio 2096 was also used to further buffer our estimate in the event that in reality we may require a larger joint It was felt that because we had neither the time nor the resources to conduct a full fledged joint design and conclusive joint mass was extremely difficult to produce 8 5 4 Resolver Mass The mass of the resolver could not be found on the manufacturer s website so a comparable resolver of similar proportions standa
110. ES SNR Q 533 22 n RSS 59 RNE 59 ABARIS RENY 4 NNN RN ERE RES WS Sh RSE 3 a RRS NNN a ANNANN 5 n E a 4 zje ag lt N 2 S Se 8 Se o e 5 2 gt fc jul wu m rg E52 E S E 5 lt gt lt 5 5 XE We iL 5 T E TE ze 2 8 E EX 3 5 uz s m I 3 puy 53 8 81 8 ul ws S 3 u z gt 0 5 E t 55 B LER 5 gt is ds jii a a a 20 25 lt gt x lum N eu ES J W e o Appendix 7 2 2 EFBD 1 Motor EU lt BUSP7A V o
111. GF or otherwise interfere with the HST capture 2 2 DR Stow Configuration The DR will be stowed on the exterior of the EM during launch proximity and capture operations This location was chosen over an interior bay to simplify the removal and return of the DR Exterior stowage eliminates the need for doors to be manipulated simplifies the configuration of the DR and gives the GA a wider work area when grappling the DR In order to secure the DR to the EM clamps will be located on the EM and corresponding towel bars on the DR Three such fixtures will be located on each arm shoulder elbow and wrist with two additional fix points on the main body The GA will signal ground control when it has securely grappled the DR and the stowage clamps will be opened by ground control Similarly when the GA has returned the DR to the stow location a signal will be sent and the clamps closed In addition to these physical connections the DR will need to be electrically connected to the EM in order to monitor and maintain the temperature of its electronics To accomplish this two connectors primary and backup each carrying a low power and 1553 data bus wire will mate 171 the DR to the EM before it is grappled by the GA The connectors will be located on the front of the DR which is facing the EM while stowed When the GA signals the successful capture of the DR GF these connections will be shut down Furthermore when the GA is returning the DR
112. HST The other arm will have a general purpose manipulator Details of both arms are in sections 8 3 1 and 8 3 2 respectively 21 8 2 2 DR GA Interface 8 2 2 1 Grapple The standard grapple fixture designed for the CanadArm 2 is used as per requirements from the GA The detailed specification of the grapple fixture is found in the ICD in Appendix 10 Modifications were made to the fixture including the elimination of the clamping feature that was originally designed to allow the grapple end effector to act as a shoulder This kind of structural support is not necessary for the mission and thus the clamps will be discarded Alignment Teeth The dominant interface force is 226 N and results from applying SOft lb of torque at the DR end effector The dominant torque is 288 Nm and F 8 2 DR Grapple Fixt these numbers include a factor of safety of 1 75 The interface will have the necessary stiffness and strength to withstand these loads The details of these calculations can be found in Appendix 8 3 7 8 2 2 2 Load Transfer 9 The DR also imposes a cable load requirement the requiring 4 kg of cabling and associated accessories to be routed through the GA This imposes structural requirements as well as adding to the force required from each of the motors Using the estimation that a 100 wire bundle requires 5 Nm of torque given by Ross Gillett we have 5 2 Nm of torque needed for the 104 wires
113. HST is at an altitude of approx 600km 3 The pressure at this altitude is very low almost zero and temperature gradients during each HST orbit can vary over 100 F as the Earth blocks out the sun s light Temperatures range at this altitude from 300 F to 300 F The DR has been designed to regulate its temperature to ranges that are survivable by its subsystems see appendix 8 5 14 The mission needs to be carried out without blocking Hubble s solar arrays communication receivers transmitters or the Tracking and Data Relay Satellite System TDRSS At Hubble s altitude the overhead atmosphere the exosphere does not provide any significant radiation protection We have therefore designed the systems of the HRV to withstand this harsh radiation environment 5 2 Functional Flow The operational process is described in detail in Appendix 1 The HRV is to be first packaged securely on the rocket launcher so that it survives the launch loads and vibrations After launch the rocket separates and the HRV will pursue the HST using its guidance navigation systems The DR remains in a keep alive mode until the GA has captured the HST and docked the HRV on its berthing pins The GA will then mate to the DR allowing it to power up and detach from the EM The GA will then position the DR as required to perform servicing operations that include power augmentation installation of the new Wide Field Camera 3 and RSU connections During se
114. J9 4 2 4 3 1 The DR End Effector shall have the ability to open Bay 1 4 2 4 3 2 The DR shall have a tool to grapple the J9 connector 4 2 4 3 3 The DR shall have a tool to grapple the 1553 connector 4 2 4 3 4 The DR shall be capable of sensing its environment to such a degree that it is able to work within the confined space of the WFC3 bay on the HST see 4 3 5 4 205 DR s tool actuator shall be capable of applying 50 ft Ib of torque 4 2 5 1 The DR Tool Drive Motor and DR Tool Drive Gearbox ratios shall be sufficient to apply this torque e Getting this kind of torque and a reasonable turn speed may influence DR power requirements 4 2 6 The DR will track the progression of its tool by monitoring the number of revolutions and the torque applied 4 2 6 1 The DR shall have a torque sensor in its tool drive mechanism capable of measuring up to 50 1 5 75ft Ib torques 4 2 6 1 1 1 5 1s estimated F O S 4 2 6 1 2 50 1 5 75ft lb 101 6865 Nm 4 2 6 2 The DR s tool actuator shall use an optical encoder tachometer stepper motor Minimum resolution of O 360 4 2 7 The DR shall be capable of stopping a 10001 mass from maximum commanded tip velocity within 2 and 2 i e it must have the strength stiffness etc to stop operations any if commanded to do so 4 2 7 1 The DR shall produce a minimum tip force of 4465 v 2 N where v is the tip velocity 4 2 7 2 The DR shall produce a minimum torque of 677 w 2 Nm where w is the angular rate
115. Layout and Cabling 1 Lower Tool Arm To Layout and Cabling 2 BUS P1A 24V BUS P1B 24V Bus D1A 1553 Bus D1A 1553 Bus D1B 1553 Bus D1B 1553 n Mj BUS 12V BUS P3A 12V 1 gt gt BUS P3B 12V i BUS P3B 12V eee BUS 28V i BUS P4A 28V gt p BUS 28V BUS P4B 28V To Layout and Cabling 2 120 Appendix 7 1 3 Layout and Cabling 2 Upper Tool Arm From Layout and Cabling 1 To Layout and Cabling 5 BUS P1A 24V Bus V1 NTSC gt Bus V2 NTSC gt Bus D1A 1553 Bus D1B 1553 Bus D1B 1553 From Layout and Cabling 1 m BUS P3A 12V RI i BUS P3B 12V i lt gt 4 cae 4 ses ulia 5 5 ds i BUS 28V i aj gt A ae z x ee ene BUS 28V To Layout and Cabling 5 121 Appendix 7 1 4 Layout and Cabling 3 Lower Manipulator Arm To Layout and Cabling 4 BUS P7A 24V BUS P7B 24
116. Strength for Allowed Deflection BENDING MaxNetDeflection 0 002 m l M L42 2 E MaxDeflection Segment Shoulder Upper Boom Lower Boom Wrist Max Deflection carbon 0 0002 3 28E 05 0 0007 1 16E 05 0 0007 6 08E 06 0 0004 1 15E 05 Radius 0 075 0 075 0 075 0 075 Aluminium 8 78E 05 3 10E 05 2 82E 05 2 82E 05 I Titanium 5 67E 05 2 00E 05 1 05E 05 1 98E 05 Note All these materials can easily handle the required loads However it is desireable to produce beams with higher moments of inertia than the calculated minimums to produce a stiffer arm The stopping distance budget allows for a net displacement of 2mm due to mechanical deflection of the arm t Titanium 3 4E 05 8E 05 8E 05 t carbon 0 0248 0 0087 0 0046 0 0087 t Aluminum 0 0003 0 0001 0 0001 t Titanium 0 0428 0 0151 0 0079 0 0150 t Aluminum 148 Appendix 8 3 4 General Manipulator Arm Calculations Basic Parameters Main Boom Lengths Arm Diameter Arm Offset Appprox Arm Length Tip Speed Tip Rotation Assumptions Stop 2005 Case Apply 50 ftlb Torque Case move 1000Ib Factors of Safety Static Margin Kinetic Margin Inertial self weight Forces on Arm are neglected Assumed small compared to end effector loads Tip Speeds adjusted to make Power draw reasonable MA Self Mass 99 50545 kg Mass Budget EE Payload 200 Ib 90 71848 kg Effective EE Payload 140 4712054 kg Payload plus half of Payload Momen
117. The last high risk factor falls into the group of command corruption and we have decided to mitigate this by having all mission commands and signals use a double positive system This way no single failed channel or misinterpreted signal can lead to uncommanded control input to the DR 5 6 Ground Control Architecture This section defines the ground control architecture that will govern how operators carry out the Dexterous Robot s repair mission DR ground control is responsible for all mission tasks while the DR subsystems will govern low level operations that maintain basic functions like thermal control We have reducing the DR to a minimum level of autonomy as this preserves the same overall mission capabilities while eliminating failure points including a number of catastrophic scenarios i e a runaway robot completing servicing tasks incorrectly and causing damage to the HST 19 The onboard systems of the DR will not be truly autonomous though they will provide real time corrections and adjustments while executing the commands issued by ground controllers Details of the DR s autonomy are discussed in section 5 4 below The following is a discussion of how the human controllers of the DR command and control the robotic system during its various activities Below is a table identifying what the mission tasks initiated by GC and those performed by on board systems without an operator in the loop Ground Control DR Mission
118. V BUS 24V BUS 24V BUS 24V 5 5 Bus NTSC gt gt ee Bus V4 NTSC Bus D4A 1553 Bus D4A 1553 lt gt lt gt lt gt lt gt N ati Gripper Manipulator Lower Arm GRIPPER MH MEU CAM 1 lt gt lt gt Bus D4B 1553 Bus D4B 1553 i i i i fn gt BUS P9A 12V Lan BUS P9A 12V 8 BUS 12V l BUS 12V i i BUS P10A 28V BUS P10A 28V BUS P10B 28V BUS P10B 28V To Layout and Cabling 4 122 Appendix 7 1 5 Layout and Cabling 4 Upper Manipulator Arm From Layout and Cabling 3 To Layout and Cabling 5 BUS P7A 24V k BUS P7B 24V 4 _ 4 Bus V3 NTSC gt 4 EMEN he ee Bus V4 NTSC gt Bus D4A 1553 DR Body Lower Arm Bus D4B 1553 Bus D4B 1553 1 1 4 f BUS P9A 12V EI m BUS P9B 12V B 1 E s m d si ij a E m i BUS P10A 28V s E 4 E A amp gt p BUS P10B 28V From Layout and Cabling 3 To Layout and Cabling
119. Voltage Regulator 3 m Pt i 4 i 3 T ax mem gt Motor Micro i ve Limit Controller i Switch bod jx gt i Limit A Y 1 Switch gt i i Motor Power 4 1 Amplifier H Winding 1 f and Switching i H Gearbox Motor i indi Vee Motor Power e Winding 2 i i Amplifier 1 velLimit and Switching Switch r4 ve Limit Em D i Motor Micro Switch le Controller 2 H geom gr P e 1 i i NE i Shs 1 20 var t Ns i Cn i Coo o T mme i er i i m Ld Voltage Regulator Voltage Regulator i i EMI Filter EMI Fiter 1 H 4 l BUS i TViEreaker st i 12 Controller 4 12 y i A i IR Emitter IR Recievers IR Emitter IR Recievers 1 1 lt 018 1553 gt L BUS 12V gt BUS P3E oon tS See St Sets p 131 Appendix 7 2 7 EFBD 6 Clamp EU
120. WFC3 7 5 into position in HST 5 3 3 13 Drive A latch into position 5 3 3 13 1 Acquire 7 16 counterclockwise ratchet tool from tool caddy 5 3 3 13 2 Position tool for driving A Latch 5 3 3 13 3 Drive tool until A Latch is closed 22 5 Turns 5 3 1 14 Drive blind mate connector into position 78 5 3 1 14 2 Position7 16 counterclockwise ratchet tool for driving blind mate connector 5 3 1 14 3 Drive tool until connector is engaged 5 turns 5 3 1 14 4 Stow 7 16 counterclockwise ratchet in caddy 5 3 3 15 Un stow ground strap 5 3 1 15 1 Capture GS with manipulator arm 5 3 1 15 2 Capture clamp tool holding GS with tool arm 5 3 1 15 3 Detach GS from rail by opening clamp tool 5 3 1 15 4 Put away clip tool 5 3 3 16 Install Ground Strap on WFC3 5 3 1 16 1 Acquire ground strap tool from caddy 5 3 1 16 2 Position ground strap on WFC3 using manipulator hand 5 3 1 16 3 Use ground strap tool and attach ground strap by tightening bolt 5 3 1 16 4 Put away ground strap tool 5 3 1 16 5 Grab hold of GS from manipulator hand 5 3 3 17 DR standby 5 3 3 18 GA standby 5 3 4 Permanently Stow WF PC2 5 3 4 1 Activate GA 5 3 4 2 Activate DR 5 3 4 3 Move GA DR to Temporary Stow Work Site at WF PC2 5 3 4 4 Grapple Interface Plate With Tool Arm 5 3 4 5 Release WF PC2 from Temporary Stow Fixture 5 3 4 6 Move GA DR to WFC bay on EM while carrying WF PC2 5 3 4 7 Push WF PC2 7 5 into position in EM bay As Above 5 3 4 8 Release WF PC2 5 3 2 9 Drive
121. al theta2 theta3 theta4 theta5 theta6 CommandedEEPos thetal deltal theta2 delta2 theta3 delta3 theta4 delta4 theta5 deltaS5 theta6 delta 2 30 0 0 1 553343034 0 0 ErroneousEEPos evalf evalm matrix 6 1 X1 X2 X3 sols 1 sols 3 sols 2 sols 2 163 gt DeltaX evalm ErroneousEEPos evalm CommandedEEPos evalm ErroneousEEPos ErroneousEEPos CommandedEEPos DeltaX 2 300000000 6 1 9696707412 10 1 1 00001260518687 1 1 553349498 5 3400800356 10 1 5 9638426275 10 rcm orm mem mem em mm mm 2 300000000 6 9696707412 10 00001260518687 1 553349498 5 3400800356 10 5 9638426275 10 0 1 2 30 6 1 1 9696707412 10 0 1 00001260518687 0 1 1 5 M 6464 10 0 1 5 3400800356 10 0 1 5 1 9638426275 10 164 Appendix 8 7 Detailed Mass Budget Detailed DR Mass Budget Tool Arm Component Type a a Mass kg Faulharber 3564 024 B FaulHarber G2 6 Faulharber 30 1 1 482 Harowe 300 P 1 789 Toshiba IK 52V 0 095 3 373 2 343 Shoulder Fairing 14 639 Elbow Joint 4 880 Upper Boom 23 771 Lower Bo
122. applications 8 311 079 Resistant to most chemicals acids solvents bases except NaOH Radiation resistant to 10 rads 4 built with polyimide insulated leads custom option Can be made in very small sizes Fluid immersible models available not standard Test or simulate integrated circuits Enable cold weather operation of outdoor electronics such as card readers or LCD s Maintain constant temperature in analytic test equipment Maximum watt density Kapton heaters WATTS SQUARE CM MAXIMUM ALLOWABLE POWER WATTS SQUARE INCH OF EFFECTIVE AREA evo SB RBRBREA SH 50 100 10 200 IF 212 HEAT SINK TEMPERATURE Example 50 C the maximum power fora heater mounted with acrylic PSA is 18 Wiirt Kapton is the DuPont tradename for polyimide Specifications for catalog models Tem 200 to 200 C 328 to 3 Upper limit with 0 003 a 0 08 m ores 150 C 5925 Materiat Kapton FEP 0 002 0 001 0 05 0 03 mm Resistance tolerance 10 or 0 5 Q whichever greater Dielectric strength 1000 VRMS Minimum bend radius 0 030 0 8 mm Leadwire Red PTFE insulated stranded Current capacily based an 100 C max ambient temp AWG30 AWG26 AWG24 AWG 20 SOA 50A 75A 135A Maximum heater thickness Over element 0 012 0 3 mm AWG 30 0 057 v bs AWG 26 0 141 ANG 20 0 565 E 20 0 563 cen box iin Dimensional tolerance 6 150 mm oriess
123. are subject to wear and require maintenance When the functions of commutator and brushes were implemented by solid state switches maintenance free motors were realised These motors are now known as brushless dc motors In this chapter the basic structures drive circuits fundamental principles steady state characteristics and applications of brushless dc motors will be discussed Structures and Drive Circuits Basic structures The construction of modern brushless motors is very similar to the ac motor known as the permanent magnet synchronous motor Fig l illustrates the structure of a typical three phase brushless dc motor The stator windings are similar to those in a polyphase ac motor and the rotor is composed of one or more permanent magnets Brushless dc motors are different from ac synchronous motors in that the former incorporates some means to detect the rotor position or magnetic poles to produce signals to control the electronic switches as shown in Fig 2 The most common position pole sensor is the Hall element but some motors use optical sensors Permanent magnet rotor i Hall elements Winding Fig 1 Disassembled view of a brushless dc motor from Ref 1 p58 Fig 4 1 48531 EMS Chapter 12 Brushless DC Motors DC Supply PM ac Motor Logic Circuit Electronic Commutator Position Sensor Although the most orthodox and efficient motors are three phase two phase brushl
124. are two video cameras on the end of each arm each camera serves as the other s back up and there is no need to have back up data bus for each camera 7 3 3 Electrical Mass Budget The total mass of cabling in the DR is 14 kg The details of these calculations are found in Appendix 7 4 This number includes wire insulation bundle shielding and connectors at all bus drop locations The wire gages were adjusted to accommodate the derating of the cable bundles Since the power and control center of the DR is located on the EM cable carrying requirements are imposed on the GA The total cabling mass imposed on the GA is 4kg The details of these calculations are located in Appendix 7 5 7 4 Fault Tolerance 7 4 1 Automatic Breakers and Fault Recovery There shall be a bus controller in each electronics box that controls all breakers Each actuator has its power breaker contained within its controlling unit such that the breaker for the control unit and actuator are co located and do not necessitate a separate breaker bus line going to both locations The recovery bus will be redundant like the power and data busses with each recovery bus RA and RB providing breaker control to the corresponding power bus PA and PB The 1553 standard will be used and will pass through the GA and will be connected to the main avionics box where its bus controller will be located The main computer will provide command and control of the breaking functions
125. arked with a certain number is exposed to light the transistor of the same number is turned OFF On the other hand when a phototransistor is not exposed to light the transistor of the same number is turned ON In the positional state of Fig 6 Tr2 3 and 6 are ON and the battery voltage E appears at terminal V while U and W have zero electric potential Then as shown in Fig 9 a the magnetic field in the stator is reversed and the rotor s torque is counter clockwise After the motor revolves about 309 Tr2 turns OFF and Trl ON At this point the field has revolved 60 and becomes as shown in b As the rotor produces another counter clockwise torque the counter clockwise motion continues and the field becomes as shown in c This action is replaced in the sequence of a b c Q to produce a continuous counter clockwise motion ON OFF sequence Fig 9 Counter clockwise revolutions of the stator s magnetic field and rotor from Ref 1 p63 Fig 4 7 The motor discussed above has A connected windings but it may also have Y connected windings Fig 10 a shows a practical circuit which is used in a laser beam printer or a hard disc drive As shown in Fig 10 b three Hall elements are placed at intervals of 60 for detection of the rotor s magnetic poles Because this motor has four o magnetic poles a mechanical angle of 60 corresponds to an electrical angle of 1207 Equivalent Cir
126. ate health data Motor micro controllers rate and angle information Gear Box Resolver Figure 6 8 Motor Control 46 6 4 4 2 Level 2 example Thermal Control Please see Figure 6 9 e Monitor Temperature This module continuously loops over the data from the thermocouples and processes this data for communication to the Adjust Temperature module Command and Data Handling This module interprets thermal commands form the other modules and the GC and sends them on to the temperature adjustment module e Adjust Temperature Based on data received from monitor temperature and commands received from the CD amp H this module will adjust the temperature on a specific device accordingly by switching on the appropriate heating element This is accomplished by making a request to the power regulation system Earth CPU data commands Thermocouples thermocouple voltage drops thermocouple voltage drops temparature data M M M M M To power regulation system heaters that need to switched TOS Figure 6 9 Thermal Control 47 6 4 5 Example Software Mini Spec See Appendix 6 6 4 6 Data Dictionary See Appendix 6 6 4 7 Software Push Down Hardware Requirements In order to complete its requirements the software shall Since the processing power of conventional radiation hardened CPUs is comparatively small compared to their earth bound brethren
127. ate system for details e Orientation data This will include final orientation indicating the angles each axis has to make with the absolute fixed axes See coordinate system for details e Volume data volume of space occupied by the DR or DR payload combination to calculate trajectory and prevent bumping into the HST 4 2 5 GA Ground Control to DR Ground Control The GA ground controllers communicate the following information to DR ground controllers e Successful capture before startup e Move command carried out successfully DR task can begin Communication protocol will require that the data will be communicated to GA ground control by the computer The receipt of the data is acknowledged before the next operation can follow Verbal communication may be added for redundancy purposes to ensure nothing is missed 175 5 CD References 1 Space Mission Analysis and Design Edition James Wertz and Wiley J Larson 2 Engineering Fundamentals www efunda com 3 Electrical Mechanical and Software Assignments HERO 2004 4 Electrical Mechanical and Software Assignments Frontier Robotics 2004 5 ICD FRGF_corl4ASTS Ch 14 AER 407 Supplemental Notes 2004 176 6 ICD Appendices 6 1 GA End Effector 6 1 1 Front View GA End Effector Front View 177 6 1 2 Isometric View Alignment Electrical Port 32 pin Electrical Port 20 pin x2 Electrical Port 32 Electr
128. ation the GA will move to the new location and then the DR will resume operations 5 3 3 DR GA emergency stop In the event of a contingency situation arising we have identified a full stop of activities as being the best hazard mitigation strategy See 5 5 Safety below For this reason the DA and GR will coordinate emergency stops so that both systems halt completely in the event of some fault being detected 5 3 4 DR stow and un grappling The DR needs to be re stowed prior to jettisoning of the EM We have designed the stowing operation to account for the accuracy capabilities of the GA See ICD in appendix 10 by making the first stow fixture have a large capture envelope The DR will be configured for stowing and the GA will then need to place the matching fixture on the DR into the initial stow fixture DR GC will then engage this initial fixture to force the DR into Figure 5 1 DR alignment with the remaining connection points The GA will then configuration for pivot the DR around the closed stow fixture until the remaining ones Placement in stow are aligned and can be engaged Once the DR is secure it will shut down all systems in anticipation of power being severed one the GA un grapples and moves into its own stow position fixtures on EM 5 4 Operating Modes 5 4 1 1 Keep alive Mode In this mode the DR be essentially inactive All CPUs motors and vision systems will be shut down to conserve power aside
129. between two busses in any case and changing the order in which the connections are distributed adds no additional complexity cost to the system The power bus voltages have been selected based on the specifications provided for each component i e 24 Volts for motors and 12 V for electronics The electronics boxes will have their own transformers to step down the 12 V according to specialized needs of the hardware The heater power bus requires 12V as well An additional consideration taken into account when selecting voltages is the gauge of wiring required to supply power to each of the devices 52 7 3 2 Data Busses 7 3 2 1 Interfaces The data busses are routed from the CPU on the EM through the GA Two 32 pin data connectors are located on the grapple fixture to transfer the data busses to the DR The pin set consists of 16 1553 data bus connections and 16 video bus connections Each connector will carry a full set of data cables allowing the DR to maintain functionality in the event of a connector fault 7 3 2 2 Design g Given the large amount of data expected from the video cameras and the LCS the LCS can output a Figure 7 2 Data Connector Locations maximum resolution image size equivalent to 1Mb we expect that they will likely need a dedicated bus to handle this heavy data transfer A similar arrangement will be followed for the video cameras with each video camera having a separate independent bus Since there
130. ctly influence the selection of a vision sensor These are outlined below Accuracy The DR must achieve e Closed loop accuracy of 0 16 or 4 06mm e Angular accuracy of better than 1 While this could be accomplished by simply having accurate sensors in the DR arms in the form of resolvers the addition of feedback provided by a vision system will make this goal significantly easier to achieve and makes the system more robust in the presence of transient disturbances to the DR arms Any vision sensor selected should be able to determine the location of a target point to about the same level of accuracy quoted above This statement neglects the full extent of the information that a vision system provides in that not only does it provide xyz coordinates for specific points but also determines corner locations edge locations and the orientation of a rigid body etc To restrict our scope and given that machine vision is a topic with a considerable amount of depth well beyond our space to examine it here it will suffice to say that our visual sensor will have an accuracy equivalent to the DR requirements Range The DR vision sensor does not require an extensive range since the majority of its operations will be conducted within and arms reach of the DR Hence the range should not exceed 5m 33 The vision sensor should however have a wide field of view such that the DR is capable of viewing its entire workspace despite being i
131. cuit and General Equations The per phase equivalent circuit is shown Fig 11 as following where is the flux linkage of stator winding per phase due to the permanent magnet For steady state conditions assuming v and e are sinusoidal at frequency 0 the equivalent circuit becomes the one shown in Fig 12 where X L and V I E and are phasors with rms amplitudes The steady state circuit equation can be written as V E R joL I 1 Page 12 6 48531 EMS Chapter 12 Brushless DC Motors Hall element Amplifier Wave shaping circuit Fig 10 Practical circuit for a three phase bipolar driven motor and arrangement of Hall elements from Ref 1 p80 Fig 5 1 L R dt Fig 11 Dynamic per phase equivalent circuit of brushless dc motors X OL I R V E jOA m Fig 12 Steady state per phase equivalent circuit of brushless dc motors For a maximum mechanical power at a given speed and are in phase This also gives maximum torque ampere minimum current Nm A brushless dc motor has position feedback from the rotor via Hall devices optical devices encoder etc to keep a particular angle between V and E since E is in phase with rotor position and V is Page 12 7 48531 EMS Chapter 12 Brushless DC Motors determined by the inverter supply to the motor Assuming that L lt lt R when is in phase with E V will also be in phase with E Thus the circuit can be analyzed using magni
132. d Astronautics NPD 8710 3A NASA Policy for Limiting Orbital Debris Generation HST Project Science office http hstsci gsfc nasa gov orbit html January 2000 A Ulitsky D King Enabling the Future Lidar Space Vision Systems for Next Generation On Orbit Servicing http www on orbit servicing com workshop_2002 OOS Docs ST6 1 4 3a pdf Prado Pewitt A High Performance COTS based Vector Processor for Space http klabs org richcontent MAPLDCon99 Presentations P16 Prado S ppt Bundle Diameter Calculator http www bit net com omegaone refs bundle_single html MicroMo Electronics www micromo com Vishay Measurements Group http www vishay com company brands measurementsgroup guide notebook e 20 e20 htm October 1994 Netcomposites Natural Fibre Injection http www netcomposites com news asp 2017 Cement amp Concrete Institute Fibre reinforced concrete http enci org za inf leaflets html fibre html Watlow Kapton Material http www watlow com literature specsheets files heaters 1702 1100 pdf AMCI Resolvers and Resolver Transducers http www amci com resolvers size 11 brushless resolvers asp ICD FRGF_corl4ASTS Ch 14 AER 407 Supplemental Notes 2004 Engineering Fundamentals www efunda com 73 Appendix 1 Functional Flow Appendix 1 1 Functional Flow Listing Chronological sequence is in the downward direction as indicated by the numbering of the items The hierarchy of the f
133. d Control 4 3 5 The DR shall have the appropriate software for performing all the function and have the following modes 4 3 5 1 Earth Control Mode The software will e continuously check for feed from earth e stop all operations if feed is lost e try to reestablish feed if lost e relay sensor signals vision torque force moment position to ground control if continuous feed present e relay commands from ground control to actuators and end effectors if continuous feed present 89 e Change to autonomous mode if feed cannot be established after a determined minimum number of attempts or if commanded to do so from Ground control 4 3 5 2 Semiautonomous mode This mode is the same as the Earth control mode except that the commands are uploaded to the DR CPU in scripted from and the DR follows the commands while people at ground station observe 90 Appendix 3 System Architecture Appendix 3 1 System Block Diagram Hubble Space Telescope Grapple Dexterous Robot WEZC Prem EH
134. d at the base of the FRGF grapple pin The x axis is along the line joining the two laser identifiers on the Grapple fixture The y axis is perpendicular to the x axis along same plane The z axis will be perpendicular to the base plate of the stow fixture The origin of the GA coordinate system is the base of the GA at the shoulder mount All coordinate axes are defined in the same direction as the Hubble coordinate system All GA positioning commands from ground controllers will be in this reference frame The absolute axes to be used in orientation calculation are defined relative to the Hubble The x axis 1s parallel to the line joining the Solar Array supports the y axis is perpendicular to the x axis and z axis is parallel to the cylindrical axis of the HST 4 2 Communications 4 2 1 Emergency Stop Command Most communications between the GA and DR is handled through ground control since most operations are not time critical and transmission lag is not a factor The only direct communication between the DR and GA computers occurs if the DR detects a possible collision with any element on the HST In that case an emergency stop signal is sent directly to the GA Emergency Systems controller that halts GA motion This will prevent any damage to the HST Since this is a time critical operation the signal is sent directly from the DR to the GA and ground control is later notified when the system has stabilized Collision detection on
135. d for the 64 wires details in Section 3 Electrical Interface routed through the GA See Appendix 6 5 for cable mass calculations 2 5 Thermal A common temperature range will be defined for both EE and GF in order to minimize thermal gradients between the GA and the DR A temperature range between 20 C and 20 C has been selected based on requirements for actuators and electronics in the EE The DR grapple fixture will equilibrate with the GA end effector once a mechanical connection has been made The temperature range for the EE during operation will be between 10 C and 65 C as required In order to isolate the GF from the main body of the DR as well as the EE from the GA ceramic blocks will separate the two structures This will ensure that any active heating of the DR electronics or structure will not result in temperature fluxes at the interface 172 3 ICD Electrical Interface We require that the FRGF interface with the GA will have in total two connectors One connector would be the primary connector for power and data 32 pins in total while the other connector is identical and will be completely redundant for both power and data also containing 32 pins This way we meet the single fault tolerant requirement so that if one connector fails the other connector can be used to continue the mission In total 36 pins are needed for power cables and 28 pins for data cables A breakdown of the connections is given in Table 3 1 belo
136. data and disseminates it accordingly through the VSOS LCS Pan Tilt Movement This module commands the movement of the LCS pan tilt mount based upon commands received from the LCS system controller or the GC via the VSOS 3D Model Matching Engine This module generates 3D models of the DR s workspace using full scan data from the LCS This data is received directly from the LCS control module and the results are sent to GC and various other modules via the communications interchange Stereoscopic Engine Solves for depth of field information given the two video streams from each camera and known baseline between the cameras Collision Detection Engine Analyzes the latest model update and tracking data for imminent collisions and communicates the results through VCOS to all interested parties Video Camera Controller This module controls the video cameras and their associated lighting on each end effector It alters the focus accordingly and receives and preprocesses visual data so that it can be sent to the stereoscopic engine External Communication The vision system is able to communicate directly with GC via this module which interacts with the radios on the EM Video data are compressed by this module and any other operations LCS Edge Tracking Engine This module contains the algorithms required to deal with the LCS tracking mode The edges identified by the LCS will be fitted to models of the objects in question and a coarse determi
137. des return line ARM 2 24V Primary 1 2 includes return line ARM 2 24V Backupl 2 includes return line ARM 2 24V Primary 2 2 includes return line ARM 2 24V Backup2 2 includes return line LCS 24V Backup 2 includes return line Connection Interface Power Requirements Power line Number of connectors for power line Low Power 115 V 16 High Power 24 V 20 Total 36 The power lines will need 18 pins for primary power system and another 18 pins for a completely redundant back up power system 6 6 2 Data Interface Number needed for requirement ARM 1 1553 Primary 2 includes return line ARM 1 1553 Backup 2 includes return line ARM 1 Video Primary 2 includes return line ARM 1 Video Backup 2 includes return line ARM 1 Sensors RS232 Primary 2 includes return line ARM 1 Sensors RS232 Backup 2 includes return line RS 422 LCS Primary 2 includes return line ARM 2 1553 Primary 2 includes return line ARM 2 1553 Backup 2 includes return line ARM 2 Video Primary ARM 2 Video Backup 2 includes return line 2 includes return line ARM 2 Sensors RS232 Primary 2 includes return line 185 ARM 2 Sensors RS232 Backup 2 includes return line 2 includes return line RS 422 LCS Backup Connector Interface Data Requirements
138. e Force Control C amp DH Command and Data Handling CU Control Unit DR Dexterous Robot DM De Orbit Module DOF Degrees Of Freedom EE End Effector EL Elbow EM Ejection Module EMI Electro Magnetic Interference EPS Electrical Power System EU Electrical Unit FMEA Failure Mode Effects Analysis FRGF Flight Releasable Grapple Fixture FTSU Force Torque Sensing Unit GA Grapple Arm GC Ground Control HRM Hubble Rescue Mission HRV Hubble Rescue Vehicle HST Hubble Space Telescope ICD Interface Control Document IR Infra Red IRED Infra Red Emitting Diodes LCS Laser Camera System MEU Motor Electrical Unit MH Manipulator Hand PWM Pulse Width Modulation RFP Request For Proposal RSS Robotic Servicing System RSU Rate Sensing Unit SP Shoulder Pitch SR Shoulder Roll TBD To Be Determined TBR To Be Reviewed TCS Thermal Control System WFC3 Wide Field Camera 3 WF PC2 Wide Field Planetary Camera 2 WP Wrist Pitch WR Wrist Roll WRT With Respect To WY Wrist Yaw 3 Mission Overview 3 1 Mission Scope The scope of the DR mission is limited to the robotic servicing portions of the Hubble Rescue Mission HRM as presented by the contractor MD Robotics in the Request For Proposal RFP 1 It will consist of the robotic mechanisms and support systems required to perform the power augmentation wide field camera change out and gyroscope installation operations during the servicing phase of the mission The DR shall operate i
139. e LCS e Have an LCS lens mounted on the top of the body capable of 90 degrees of pan and 45 degrees of tilt 6 1 5 Time Domain Requirements The repair operation will occur slowly over the course of a month therefore a system that responds in an ultra fast fashion is not required and is likely to add complexity to our system Given this we have decided upon the following time domain response 28 6 1 5 1 Settling Time In order to complete the HST servicing operations in a reasonable amount of time the lag time should be no greater than 5 seconds 6 1 5 2 Rise Time The rise shall be less than 2 5 seconds This is deemed to be an acceptable rise time 6 1 5 3 Bed Time This shall gradually increase without bound while I nw 6 1 5 4 Steady State Error Requirements The steady state error is interpreted as the cumulative error in tip position caused by the steady state angular errors of each joint in the arm For a cumulative error less than 1 as requested by the customer a higher accuracy is required at the shoulder joints as compared to the wrist However we have decided to apply the highest level constraint to each joint to improve the overall accuracy of the arm Given our arm s length the steady state error allowed in each joint is 0 0466 degrees 6 1 5 5 Frequency Domain Requirements The control system shall be stable for obvious reasons and this necessitates that there be no poles in the right hand pla
140. e accu i E 1 d l 1 5 1 s 1 2 9 8 i 6 6 i a 8 l 2 E gt 1 1 Voltage Voltage Regulator Regulator 1 Filter Filter I 1 5 5 5 5 5 5 12V Breaker 44 12V Breaker 2 235 T 25 gt gt gt 6 d l Oll O 88 a8 i a a a lt am a 9 o 4 2 SSS SSS RSS SSS ASSESS vid SSSSSSSSSSSBESSSSSCSSSSSSSNNS RSs RS SABE 0 qw ANANN IA NNA NANNI ITI AAN SS LESS Snes oy Rs NANN NANNAN YIN SSS SSS RABY RGSS ERR 134 Appendix 7 2 10 EFBD 9 Force Torque Sensor Unit Bus D1A 1553 BUS Controller v Force Torque Force Torque Sensor Backup Sensor FTSU Micro FTSU Micro Conotroller iE Conotroller Backup Backup Lo qSeccoeeeeeeeeeceooec een nl Pe ne ee ee et tee 1 1 Ree ee Py ot oe Pd Se bm dl 1 1 Voltage Regulator Voltage Regulator 1 Filter Filter BUS 12V B
141. e the directions of the magnetic fields generated by the currents in each phase The fat arrow in the centre is the resultant magnetic field in the stator Page 12 4 48531 EMS Chapter 12 Brushless DC Motors Instruction of revolving direction ec wu 3 3 Phototransistors Revolving shutter Fig 6 Three phase bipolar driven brushless motor from Ref 1 p61 Fig 4 4 The rotor is placed in such a position that the field flux will have a 90 angle with respect to the stator s magnetic field as shown in Fig 7 In such a state a clockwise torque will be produced on the rotor After it revolves through about 30 PTS is turned OFF and PT6 ON which makes the stator s magnetic pole revolve 60 clockwise Thus when the rotor s south pole gets near the stator s south pole goes away further to create a continuous clockwise rotation The ON OFF sequence and the rotation of the transistor are shown in Fig 8 Direction of stator s magnetic field Torque Magnetic field Fig 7 Stator s magnetic field in the shutter state of Fig 6 and the direction of torque from Ref 1 p62 Fig 4 5 Fig 8 Clockwise revolutions of stator s magnetic field and rotor from Ref 1 p63 Fig 4 6 Page 12 5 48531 EMS Chapter 12 Brushless DC Motors The rotational direction may be reversed by arranging the logic sequencer in such a way that when a photodetector m
142. e to be performed while being supported by the GA and therefore have to satisfy interface requirements from the GA team 4 1 2 Performance Requirements The DR shall DR P1 Capable of maneuvering arm s anywhere in the workspace accuracy of 1 relative to commanded position resolution better than 0 1 and 0 1 DR P2 Torque drive of 50 ft Ib and DR 5 1 track the progression of tool by counting turns and monitoring torque DR P3 Be capable of stopping 100016 mass from maximum commanded tip velocity within 2 and 2 DR P4 DR shall be capable of limiting forced normal to constrained translational paths to no more than 10lbs and delivering up to 25165 along those paths DR P4 1 Shall have a six axis force and torque sensor near end effector to sense the torque and force at end effector with accuracy of less than 2lbs and 2ft lb as measured at end effector DR P5 Consume less than 300W that has been assumed to be the current power budget DR P6 Weigh less that 500 which we assumed is the mass budget allowed The detailed requirement tree derived from these requirements can be found in Appendix 2 4 2 System Architecture 4 2 1 Functional Decomposition The following are the basic functions that the system needs in order to complete the mission Vision system The DR will be equipped with two camera systems that include one laser camera system LCS and four mini cameras The LCS by Neptec provides xyz workspace data The LCS has a ran
143. e use the approximation that f 1 041676 2 91767 r we can calculate that for t 2 5 seconds and 6 1 we find that n n is at least 1 4 rad sec We should have a higher n for a quicker rise time The settling time requirement to be no greater than 5 seconds imposes that PNE 4 56 0 9 rad sec Of course will be greater to meet the initial requirement I mass of upper boom x length 2 2 motor inertia 2 58 kg m For a simplified model with no noise or disturbances we can assume the functional flow block diagram 104 0 actual controller Transfer Fen Integrator Fagle Position signal from Processor v Ko _ 0 00185 15 1 s 0 387156 c 0 000205 The forward transfer function becomes 0 00185 5 5 0 387156 c 0 000205 For the stead state error requirement of 0 0046 degrees we meet this because our forward transfer function has a zero pole meaning this system is of type 1 and hence has a steady state error of zero for position control The final closed loop transfer function is o s _ 0 00185P Odes s 5 0 387156 c 0 000205 0 00185 P For 0 00185P gt gt 1 96 gt 1059 The damping ratio required is 1 and hence 0 387156 0 000205 26 and so c gt 7 232Ns m We take P to be 1500 and we take C 10 to exceed the boundaries required The final transfer function is Os _ 2 775 Ades s 52 3 8725 2 775
144. ea of DR A 0 2 4 72 2I1x 0 1 23 03 Hot case App x1353x0 3x 4 max Earth gt DR F Earth gt DR 0 85 Hence qana 6x3 03x1353x0 3x0 85 1045 4a W 158 Cold case lamin X 1353 023 sor Earth DR 0 5 hence 471 50 W Earth Emitted IR Additional Assumption Earth average surface temperature is 260K Esurface IR surface emissivity of DR Hot case E surface x 5 67021x 10 x 2604 Earth gt DR Where 0 85 Hence grma 667 35 Ene W Coldcase X Apr X Fig X 5 07021x 10 x 2604 surface a Where F 5 0 5 Hence 392 6 pp W Radiated heat from DR surface area to space sink a Ape Ta S TESTO surface Energy balance for hot case a Using an MLI blanket to reduce radiation loss we can do the energy balance for the MLI as shown in the equation below s max d IR 28 d pR MLI Q emitted 4 1277 1045 667 35 Or 2322 4a 667 356 EprEnu X1 7181x107 1 7181 107 X Tur x1 7181 x107 21 7181 x10 7 xT MLI 4 pg MLI Tos surface surface If we paint the MLI outer surface white to reduce the solar absorption of sunlight we can simplify the equation further using 0 04 0 92 and a 0 2 Requiring that surface 330K we can get an expression for T
145. easons of simplicity this processor although vastly over computationally powered was also selected as the CPU for the Main command CPU See Appendix 9 for detailed specification of the system CPUs and memory board 48 7 Electrical Subsystem 7 1 Electrical Requirements e The DR shall have single fault tolerance in its electrical subsystem o The DR electrical subsystem shall use resettable circuit breakers for overcurrent protection o The DR electrical subsystem shall be completely redundant o Motor redundancy shall be obtained through dual windings The DR cables bundles shall be small enough in size so that the force required to bend them is less than 10 N e The DR cable bundles shall have 0 15 m slack at the joints to allow for full mechanical range of motion shoulder roll 180 shoulder pitch 135 elbow 135 wrist roll 180 wrist pitch 135 wrist yaw 135 e The DR cable mass shall not be more than 5 of the total DR mass e The DR electrical subsystem shall be capable of supplying power to all 6 joint motors in one arm simultaneously o The tool arm power buses shall provide a maximum of 142 W to the motors o The manipulator power bus shall provide a maximum of 108 W to the motors o The DR power bus system shall carry 24 volts over the length of the arms e The DR shall be able to command its motors at a continuous range of speeds from zero up to the maximum speed of a given joint o The motor electrical units shall vary current to
146. edundancy vs Redundancy through Duplication It was decided to go with a simple failure tolerant system whereby all electrical systems are duplicated in order to exclude the possibility of introducing unknown or poorly understood failure modes Additionally the duplication of primary systems as backups allows for simpler analysis which increases confidence in the predicted performance of the system 7 6 2 Centralized Device control vs Distributed Device Control A distributed architecture was chosen for devices such as motor electrical controllers sensor controls and TCS control units This was selected in order to reduce the number of micro controllers producing heat in a centralized location 1 e CPU as well as to increase the reliability of the control system by spreading tasks across a large set of specialized micro controllers Additionally the co location of devices and their associated controllers reduces overall cabling A distributed arrangement requires only one data bus running along the robot rather than a host of cables to allow each sensor to communicate with centrally located micro controllers 56 8 Mechanical Subsystems 8 1 Mechanical Requirements The mechanical requirements imposed on the design to meet customer s request are listed below 1 The DR shall have closed loop accuracy of 0 16 2 Linearly retract WF PC II 7 5 in the plane of WF PC II 3 The DR s tool actuator shall be capable of applying 50 ft Ib o
147. effect of L gt 0 and L gt R as speed increases A brushless dc motor has 3 phases and 6 poles The electromagnetic torque is 4 Nm with a current of 0 5 A rms Friction and iron losses produce a constant retarding torque of 0 1 Nm The resistance and inductance per phase are 70 Q and 50 mH Assume optimum position feedback Calculate a the torque and emf constants b the emf generated for a speed of 600 rpm c the speed of the motor for a supply voltage of 200 V ac rms per phase with no external load d the speed current and efficiency for an external load of 4 Nm and a supply voltage of 200 V ac rms e the supply frequency for d and check oL R Page 12 14 ENGEL Planetary Gearheads 7 081 oz in Motor and Gearhead combinations G6 1 fits motor series GNM5440 amp GNM5480 Series G6 1 See beginning of the PMDC Gearhead Section for Ordering Information G6 1 Housing material metal Backlash at no load lt 1 5 Shaft load max radial Ibs 180 axial 165 33 7 for ratio 8 1 45 0 for ratios 16 8 to 45 3 56 3 for ratios 68 9 and up Series G6 1 with Motor Series GNM 5440 length output torque reduction ratio weight with continuous intermittent direction efficiency without motor operation operation of rotation motor GNM 5440 max reversible Kg mm in Nm oz in Nm oz in 96 134 5 1 3 20 112 9 287 11 3 50 7 081 130 18 410 55 187 5 1 3 20 112 9 287 1
148. ell as physical data the BAE SYSTEMS wafer acceptance methodology assures product quality before assembly begins Every lot is continuously monitored for reliability at the wafer and assembly level using test structures as well as product testing Test structures are placed on all wafers to allow correlation and checks within wafers wafer to wafer and lot to lot Fully screened V level and Q level procedures are available to meet customers needs Lower cost engineering devices also are available for system breadboards and engineering models Every lot is continuously monitored BAE SYSTEMS Cleared for Public Domain Release DoD 98 S 3120 7 98 2000 BAE SYSTEMS All Rights Reserved BAE SYSTEMS An ISO 9001 AS9000 ISO 14001 and SEI CMM Level 4 Company 9300 Wellington Road Manassas VA 20110 4122 866 530 8104 http www baesystems iews com space 0980 Rad Hard SRAMSs ppt The property data has been taken from proprietary materials in the MatWeb database Each property value reported is the average of appropriate MatWeb entries and the comments report the maximum minimum and number of data points used to calculate the value The values are not necessarily typical of any specific grade especially less common values and those that can be most affected by additives or processing methods Physical Properties Density Mechanical Properties Hardness Barcol Tensile Strength Ultimate Tensile Modulus Flexural M
149. en the low power usually found in data busses the likelihood of a short at the CPU interconnect not a direct connection however both busses are connected to the same processor which would render both busses un operational is also unlikely 7 5 Power Demand The power demand during key mission tasks was evaluated by summing the max power of the active components All of the EPCE and their corresponding power requirements are listed in Appendix 1 3 A graph of the peak power demand vs time with is given in Figure 7 3 Key mission tasks are identified and described in Table 7 3 54 Power Peaks p MM 11 e a i a Figure 7 3 Peak power demand vs Time Mission Operation Start up and checkout B Deploy Diode Box Ops D WFC Ops Table 7 4 Key Mission Operations The average power needed during the mission is given in Figure 7 5 The overall mission average power is given by the horizontal line as 145 W This graph illustrates the power demand at each mission step To determine these values a list of components that will be drawing power at each step was made and the power added up for each stage to give the total power demand during that stage 55 Moving Average of power E m a c m a gt t Time units Figure 7 5 Average Power Demand 7 6 Design Tradeoffs 7 6 1 Complex Multiple R
150. engaging backup systems and coordinating this complex switching task with the power regulation module Power Regulation System This module will act as the central governor of all power on the DR It will know how much power is available and will supply power to devices based on requests from their respective commanding modules i e the motor command module would request power for a motor and then would handle the control of that motor and will have control of the central switching mechanisms Each commanding module in the main controller must interface with the power controller and hence this module is of central importance and should require extensive verification and validation By having all power controlled through one software module we can avoid the possibility of an error leading to the DR exceeding its power limit and potentially damaging other systems on the HRV Collision Avoidance This software element interprets data from the infrared emitting diode IRED sensors and heavily preprocessed data from the vision system and detects a potential collision situation This information and is reported to GC and GA via the communications module and immediate corrective actions are sent to the motor command module generally a full stop Thermal Control This module handles the monitoring the thermocouple sensors and requests that various heaters be turned on in order to maintain a optimal operating temperature Communications This module
151. ensor interfaces domestic appliances clocks security systems bicycle computers automotive controls TV amp audio remote controls measurement equipment R F and IR control motor driving Figure 1 Architecture _ 32kHz ROM RAM Nye Ves Vs _ Crystal Osc 2k X 16Bit 96 X 4Bit Power Supply VLD 3 Levels Power on Prescaler Reset n Core m 8 Bit Event one Coun Time EM6600 Buzzer Interrupt Watchdog Controller Timer Serial Write Buffer Port A Port B Port C Port D Port E nx 0123 123 012 3 0123 High Drive Clk Buzzer Outputs Data Figure 2 Pin Configuration V 24 VDD Paone V 28 VDD PA1 2 23 VREG PA1 2 27 VREG PA2 3 22 RESET PA2 3 26 RESET PA3 4 21 PD3 4 25 5 20 PD2 PEo 5 24 PD3 PB1 6 EM6607 td PD1 6 23 PD2 7 1 7 22 TEST 9 16 PC2 PB3 9 20 PE2 QOUT 15 PC1 1 19 14 PCO 1 18 2 VSS 2 13 STB RST QOUT 17 1 QIN
152. er 0 8 micrometer 0 5 micrometer CMOS and multi chip packaging qualification QML qualification means that quality is built into the production process rather than verified at the end of the line by expensive and destructive testing of individual products QML also means continuous process improvement focusing on enhanced quality and reliability along with shortened product introduction and cycle time Manufacturing Process Wafer Fabrication Our plant provides a clean room facility of more than 25 000 square feet including the latest advanced lithographic equipment Using Statistical Process Control SPC our wafer fabrication process assures quality and reliability in real time rather than after screening and qualification at the end of the manufacturing process Rad Hard Specifications SRAMS Total Dose rad Si SEU errors bit day Dose Rate Upset rad Si sec Survivability rad Si sec Neutron Fluence Rad Hard 1M Static RAM Assembly BAE SYSTEMS offers QML qualified high pin count flip chip wire bond assembly and high QML qualified multi chip packaging supported by inline assembly monitors and SPC Our package development methodology addresses the electrical and physical parameters of each package used in production Quality Assurance Our product assurance system encompasses all employees operators process engineers and assurance personnel Using inline electrical data as w
153. eractive Serial Write Buffer transmission Dimensions of SOP24 Package SOIC Dimensions of TSSOP24 Package Dimensions of SOP28 Package SOIC Dimensions of TSSOP28 Package 06 04 Rev B Copyright 2004 EM Microelectronic Marin SA www emmicroelectronic com 43 43 44 45 47 47 47 Table of Tables Table 1 Table 2 Table 3 Table 4 Table 5 Table 6 Table 7 Table 8 Table 9 Table 10 Table 11 Table 12 Table 13 Table 14 Table 15 Table 16 Table 17 Table 18 Table 19 Table 20 Table 21 Table 22 Table 23 Table 24 Table 25 Table 26 Table 27 Table 28 Table 29 Table 30 Table 31 Table 32 Table 33 Table 34 Table 35 Table 36 Table 37 Table 38 Table 39 Table 40 Table 41 Table 42 Table 43 Table 44 Table 45 Table 46 Table 47 IntRq register Watchdog register WD Internal state in Active Stand by and Sleep mode PortA Inputs RESET options metal Hardware option Watchdog Timer Option software option Software Power On Reset Initial Value after RESET Prescaler interrupts source Prescaler control register PRESC Watchdog register WD Input Output Ports Overview Option register Option PortA input status register PortA PortA Interrupt request register IRQpA PortA interrupt mask register MportA PortB input output status register PortB PortB Input Output control register ClOportB Ports A amp C Interrupt PortC input output regis
154. erface on WFC3 Bay 1 covering Robotic Tools 4 2 9 2 2 Via tools to release secure different parts that include see Section 4 3 3 4 2 10 The DR should not weigh more than 500 KG Possible allocation scheme 4 2 11 The DR should not consume more than 250W at any time 4 2 11 1 The DR should operate at a maximum of 160W during nominal operations or survival mode Power consuming components will include 4 2 11 1 1 Sensors touch position video camera 3D LCS 4 2 11 1 2 Actuators motors 87 4 2 11 1 3 Thermal control heating systems 4 2 11 1 4 Computer CPU 4 2 11 2 The DR shall not consume more than 250W Power consuming elements are the same as above 4 2 11 3 The DR will draw its power from the interface between the GA and DR refer to 4 1 3 3 4 3 Miscellaneous requirements 4 31 The system will have a vision system capable of supporting both controlled and semi autonomous operations 4 3 1 1 DR vision system requirements 4 3 1 1 1 DR vision system shall be capable of viewing most components of the DR arms body and workspace 4 3 1 1 2 The DR vision system shall be capable of distinguishing between the GA DR HRV and HST at all times using 3D model matching 4 3 1 1 3 The DR vision system shall be capable of operating in both night day and high glare conditions while in space 4 3 1 1 4 The range of each vision sensor will be partially covered by other sensor in the event of a single failure such that the vision s
155. es and effects were listed The severity of all potential DR failure effects was very high due to the importance of not harming the HST See Appendix 4 for the severity index scale 5 5 2 2 Hazard Mitigation The second part of the FMEA involved outlining strategies for controlling each hazard The potential causes of the failures were outlined completing the identification and organization task We first considered ways to eliminate the hazards from the mission entirely If this was not possible design features were identified that could remove or control the hazard Finally in some instances neither of these options was possible so we considered methods of reducing the damage caused by the hazard See Appendix 4 1 for the control index We then assigned a risk index to each series of control actions based on the three categories discussed above This allowed for easy identification of the most serious risks to the mission All but one of these high risk failures fall into the group of communication failures during operations of the DR These pose the highest risk to the mission because short of having an entirely redundant communication system the possibility of failure cannot be eliminated Furthermore the frequency of these actions is very high increasing the likelihood of a failure during their operations Therefore our overall hazard control strategy is to have the DR cease all motion and await further instructions from ground control
156. ess dc motors are also very commonly used for the simple construction and drive circuits Fig 3 shows the cross section of a two phase motor having auxiliary salient poles Comparison of conventional and brushless dc motors Although it is said that brushless dc motors and conventional dc motors are similar in their static characteristics they actually have remarkable differences in some aspects When we compare both motors in terms of present day technology a discussion of their differences rather than their similarities can be more helpful in understanding their proper applications Table 1 compares the advantages and disadvantages of these two types of motors When we discuss the functions of electrical motors we should not forget the significance of windings and commutation Fig 3 Two phase motor having auxiliary salient poles from Ref 1 p95 Fig 5 22 Commutation refers to the process which converts the input direct current to alternating current and properly distributes it to each winding in the armature In a conventional dc motor commutation is undertaken by brushes and commutator in contrast in a brushless dc motor it is done by using semiconductor devices such as transistors Table 1 Comparison of conventional and brushless DC motors Conventional motors Mechanical structure Field magnets on the stator Brushless motors Field magnets on the rotor Similar to AC synchronous motor Distinctive features Quick res
157. f Check 5 2 1 3 Move GA DR to conduit stow site 5 2 1 4 Remove conduit stowage fixtures 5 2 1 5 Grapple conduit with manipulator arm 5 2 1 6 Repeat installation procedure for each attachment point as required 5 2 1 6 1 Move GA DR to conduit attachment work site 5 2 1 6 2 Acquire a clip tool from tool caddy 5 2 1 6 3 Attach conduit to rail using a clip tool 5 2 1 7 Stow loose conduit cables for next tasks 5 2 1 8 DR standby 5 2 1 9 GA standby 5 2 2 Diode Box V2 75 5 2 2 1 Attach connector interface plate 5 2 2 1 1 Activate GA 5 2 2 1 2 Activate DR 5 2 2 1 3 Move GA DR to diode box opening fixture stow site 5 2 2 1 4 Grapple V2 diode opening fixtures 5 2 2 1 5 Open V2 diode box 5 2 2 1 6 Stow opening fixtures 5 2 2 1 7 Move GA DR to conduit connector plate stow site 5 2 2 1 8 Remove connector stowage fixtures 5 2 2 1 9 Grapple connector 5 2 2 1 10 Install conduit attachment point to DBA II 5 2 2 1 11 Stow any remaining fixtures 5 2 2 1 12 DR standby 5 2 2 1 13 GA standby 5 2 2 2 Attach cabling harnesses to HST handrails 5 2 2 2 1 Activate GA 5 2 2 2 2 Activate DR 5 2 2 2 3 Attach Cable 4 points repeated 5 2 2 2 3 1 Move GA DR to harness attachment work site 5 2 2 2 3 2 Acquire a clip tool from tool caddy 5 2 2 2 3 3 Attach harness to rail using a clip tool 5 2 2 2 4 Stow any remaining fixtures 5 2 2 2 5 DR standby 5 2 2 2 6 GA standby 5 2 2 3 Complete diode box power connection 5 2 2 3 1 Activate GA 5 2 2 3 2 Activate DR
158. f failure Members of this team need to be trained and practiced at using the communication equipment They should also be flexible and creative in case of deviations from the mission plan personnel associated with this mission should have a multidisciplinary engineering and problem solving background 5 6 3 1 Personnel Profile and Activities The execution of tasks during the HRV mission will be performed by robotic arm However a ground team is needed to monitor and support the actions of the GA and DR Specialized personnel will be needed to prepare the GA and DR for launch These people will perform manual safety and operational checkouts and stow the DR on the HRV This group should have a broad technical skill set for the installation Also these people should have a thorough understanding of the procedures to be performed during the mission in order to effectively test the robotic arms During the mission from launch to the EM Jettison ground controllers will direct DR This team is also responsible for manually operating the robot in the event that the primary control system fails Members of this team need to be trained and practiced at using the communication equipment and in controlling and commanding the various DR subsystems They should also be flexible and creative in case of deviations from the mission plan All technical personnel associated with this mission should have a multidisciplinary engineering and problem solving
159. f torque 4 Resolution accuracy of Force Moment at end effector shall be at least 2lbs and at least 2ft lb 5 The DR should not weigh more than 500 KG 6 The DR motion should have a resolution of 0 1 inch and 0 1 degree 7 The DR motion should be accurate to 1 degree and 1 inch 8 within 2 inches and 2 degrees 8 2 Physical Architecture 8 2 1 Overview of Mechanical Design The dexterous robot will have a pair of arms approximately 2 4 meters in length each with 6 degrees of freedom The main segments between shoulder and elbow and between the elbow and wrist will be 85 cm in length One arm will project from each side of the DR body allowing for a full range of motion on either side of the robot Figure 8 1 depicts the overall look This configuration allows the DR to fully retract install the wide field camera in a single continuous motion without requiring re positioning of the base See Appendix 82 for diagram demonstrating the maneuver used to determine arm sizing The six degrees of freedom will be Figure 8 1 DR Overview The DR must be able to stop a 100016 mass from the maximum commanded tip velocity UM ain Stow ixture accomplished with a set of two one axis joints in the shoulder one joint at the elbow and three more at the wrist One arm will have a tool grappling mechanism at its end allowing it to pick up and drive the various tools used to service the
160. face The supply voltage range for the integrated electronics is min 5 max 30 V DC Recommended values Speed range Ne 500 6 500 rpm Torque up to Me max 2 8 3 0 3 3 oz in Current up to thermal limits le max 1 30 1 00 0 60 A 8 000 E g g 6 000 3 3 3 2l el 2 4 000 o o o 2 000 0 71 1 42 2 12 2 83 3 54 0 71 1 42 2 12 2 83 3 54 0 71 1 42 2 12 2 83 3 54 Torque oz in Torque oz in Torque oz in Recommended Speed Torque Range EV 4x Caution 016 0 4 157 DEEP Incorrect lead 0 0 05 connection will damage 931 02 630 0 004 90 3 motor electronics 1 220 A g4 0 001 orientation with respect 157 to motor leadwires PVC lead wire 0 25 mm 90 05 not defined red 1 024 black c 5521 7 2 Esi 12 6 0 3 217 276 496 gam 200 10 8 53 10 5 14 03 Rear View 7 874 2 087 3153 K 551 Front View Electronics Inc 14881 Evergreen Avenue Clearwater FL 33762 3008 Toll Free 800 807 9166 Fax 727 573 5918 info micromo com www micromo com For notes on technical data refer to Technical Information Specifications subject to change without notice MME0104 Planetary Gearheads FAULHABER 40 For combination with DC Micromotors 2338 2342 2642 2657 3557 Brushless DC Servomotors 2444 3056 3564 DC Motor Tacho Combinations 2342 EE 30 1 30 1 Housing material Geartrain material Recommended max input s
161. from the minimum necessary to run the Thermal Control System 17 TCS This mode will be used during the launch pursuit proximity and capture phases while the DR is a payload on the EM 5 4 1 2 Standby Mode In this mode the DR will monitor its temperature and power heaters as needed to maintain its minimum temperature All processors are on and the DR is essentially just awaiting the next command from ground control 5 4 1 3 Normal mode In this mode the DR will perform its servicing operations making use of its full set of on board autonomous capabilities Arm motions and forces will be autonomously corrected as outlined in section 5 5 below 5 4 1 4 Manual mode In this mode operators will be able to control some or all subsystems on the DR directly in the event of primary control systems failure or if some contingency operation calls for it 5 4 1 5 Safe Mode In the event of a fault being detected on the DR it shall cease all motion to ensure no harm comes to the HST send a notification signal to the GA and to GC The DR will then send telemetry to GC and await instructions In the event of a stop during some major operation ground controllers will need to decide an appropriate course of action sufficiently quickly to prevent damage such as having the system freeze to death 5 5 Safety 5 5 1 Operational Scenarios Many different operating scenarios may take place during the mission The nominal operations scenario is
162. g method Electromagnetic method Number of disks 2 4 Fig 18 A brushless dc motor used for 8 inch hard disk drives from Ref 1 p87 Fig 5 10 REFERENCES 1 T Kenjo Permanent magnet and brushless dc motors Oxford 1985 2 TJ E Miller Brushless permanent magnet and reluctance motor drive Oxford 1989 Page 12 13 48531 EMS Chapter 12 Brushless DC Motors EXERCISES l Describe the essential features of a brushless dc motor alternatively called a self synchronous motor What additional features would be required for a brushless dc servomotor with torque and position control Sketch the power circuit for a 3 phase brushless dc motor Calculate the supply frequency required for a twelve pole motor to rotate at 360 rpm 6 3600 rpm A brushless dc motor has 3 phases and 4 poles The generated emf is 220 V rms sinusoidal at 1000 rpm open circuit voltage when tested as generator with a drive motor Calculate a the emf constant V Rad s b the torque constant Nm A with optimum position feedback angle c the speed torque curve if the resistance per phase is 4 d the supply frequency at 1000 rpm e curves of input power output power and efficiency against torque assuming friction and iron losses are zero f the frequency and speed at which X oL is equal to the resistance R if the phase inductance is 5 mH g what is the effect of f on the speed torque curve i e the
163. ge of 30m and an accuracy of 2mm within a 5m range See Table 6 1 for details Two mini cameras will be located at each end effector These will be used to provide video feedback to GC System Interfaces To perform the required operations the DR has to interface with the surrounding systems including HRV HST GA and GC The most important interface for the mission is the interface between the GA and DR This interface is basically a modification of the FRGF The details of the ICD can be found in Appendix 10 Communication System The communication system has three parts 1 Communication within DR The various parts of the DR have to be able to communicate with each other and the CPU Most of the components of the DR are connected to the central computer via a MIL 1553 data bus The LCS requires a high data transfer rate and high processing power Thus it will have a separate CPU and will be connected to the vision system CPU using a separate MIL 1553 data bus The vision system CPU and the main CPU will be in communication with each other in the avionics box 2 Communication with GA The DR CPU and the GA CPU will be in communication to notify each other of new coordinates and emergency halt commands 3 Communication with GC The communication with GC will be achieved using the EM communication module This is necessary to keep GC aware of the current situation and to receive and new scripts and commands from GC Survival system The
164. gearbox which completes speed reduction and is coupled to the output shaft Since our gearboxes are non backdrivable we do not require actual brakes on the DR This necessitates that our boxes have greater strength and ability to safely absorb the energy of a stopping maneuver We believe that with sufficient design effort this problem can be adequately solved without developing any new technologies The tool arm end effector is shown below in Figure 8 3 Secondary clip actuator Figure 8 3 Tool arm end effector The tool end effector will consist primarily of a gripper mechanism and two mini cameras The gripper design includes a primary tool gripper that will actively hold any tool while it is being manipulated This is where the common tool interface is grappled As well there is a secondary actuator designed to open the multi purpose clip tool 60 With this gripper in the open position the primary gripper is able to grab the clip tool such that the secondary actuator is in position to open the tool By activating only the secondary grip the clip tool can be opened and closed while still held securely by the end effector The mini cameras are oriented 180 from each other tilted inwards In this configuration the cameras can view worksite immediately in front of the end effector A ring of white LED s mounted in the outer shroud of the end effector will illuminate the workspace The sensitivity of the end effector positio
165. hanisms Force Torque EE Radiative Heat Loss Sensor 3 6 D O F Force dan TOS XS E Sensor Pointing A Camera Angie u Ejection Module peres esteem Lm mue m tere Docking Latches pes Sens Sensor and Hardpoints pum Im Actuators EPS Ego DR AEG System f 1 Ground Control LEGEND Blocks External to but interfacing with the RSS Blocks Representing Subsystems Components gt External Environmental Arrows Interfaces to the RSS Internal Interfaces between Subsystems of the RSS ierace L spot aroma Internal Interfaces between Subsystem Components E Gern Blocks Representing Subsystem 10 4 3 DR Characteristics 4 3 1 Physical Architecture Figure 4 2 Front view of DR Figure 4 3 Rear View of the DR 12 This section summarizes the physical architecture of the DR and briefly describes the five major physical structures the main body tool arm gripper arm head housing the LCS and grapple fixture Figure 4 2 shows the front view of the DR Here the six joints of both arms are visible along with the tool caddy and the LCS mounted on the head We can also see the various stowage fixtures Figure 4 3 s
166. high level diagram shows the location of all subsystems and the connections between them These electrical subsystems have been further decomposed to show the connections and redundancy of the EPCE on the DR The characteristic subsystems are listed in Table 7 2 with their corresponding appendix 50 Appendix oad EFBD 1 Motor EU EFBD 2 Thermal Control System EFBD 3 LCS EU Control Unit EFBD 4 Tool Caddy EU Table 7 2 EFBD Breakdown The following component descriptions are characteristic of those seen in the EFBD s 7 2 3 1 Circuit Breakers Each electrical unit will have two circuit breakers located between each unit and its power bus One breaker will be primary and the second backup forming the connections to the primary and redundant power busses In the event of an overload the breaker will trip sending a signal to the bus controller At this point either the backup bus will be activated or the breaker will be reset The breakers will be capable of being reset by the bus controller discussed below 7 2 3 2 Bus Controllers Every electrical unit will contain a primary and backup bus controller The job of this controller is to facilitate the transfer of information between the micro controller s and the data bus In addition the bus controller will receive a signal directly from the circuit breaker if an overload has occurred 7 2 3 3 Voltage Regulators Voltage regulators are located after each circuit breaker primar
167. hows the rear view of the grapple fixture with the two target points two power connectors and two data connectors The body houses the tool caddy the two shoulder roll motor and the power and data busses going to the arms and the LCS The length of the body is 140 cm and has a diameter of 58cm The arms have a total span of 2 4m They have 3 main segments shoulder arm booms wrist and end effectors The arm booms each have a length of 85 cm The shoulder and wrist roll motors have a range 180 the shoulder pitch the elbow and the wrist pitch and yaw motors each have a range of 135 giving the DR the range of motion necessary to complete the mission The LCS mounted on the head is controlled by two motors enabling it to pan 90 and tilt 45 This ability gives the LCS a large field of view which is highly beneficial for the mission The grapple fixture is a modified version of the FRGF The chief modifications being two targeting points two data bus connectors two power bus connectors and 24 gripping teeth The purpose of the gripping teeth is to prevent rotational motion while mated to the GA The DR has two specialized end effectors one for handling tools and payloads and the second is a general purpose gripper to hold loose objects stabilize payload and assist vision system with its two cameras 4 3 2 Power Budget The total average power needed for the DR servicing mission is 145 W 4 3 3 Mass Budget The total mass of
168. ial Input or Output port as a whole port Write Buffer Debounced or direct input selectable reg Each interrupt request is individually selectable Interrupt request on input s rising or falling edge selectable by Interrupt request flag is cleared automatically on register register read Pull up pull down or none selectable by metal mask if used as input CMOS or N channel open drain mode 06 04 Rev Copyright 2004 EM Microelectronic Marin SA 2 www emmicroelectronic com Table of Contents 1 PIN DESCRIPTION FOR EM6607 2 OPERATING MODES 2 1 ACTIVE MODE 2 2 STANDBY MODE 2 3 SLEEP MODE 3 POWER SUPPLY 4 RESET 4 1 OSCILLATION DETECTION CIRCUIT 4 2 RESET PIN 4 3 INPUT PORT PAO PA3 RESET 4 4 WATCHDOG TIMER RESET 4 5 SOFTWARE POWER ON RESET 4 6 CPU STATE AFTER RESET 4 7 POR WITH POWER CHECK RESET 5 OSCILLATOR 5 1 PRESCALER 6 WATCHDOG TIMER 7 INPUT AND OUTPUT PORTS 7 1 PORTA 7 1 1 PortA registers 7 2 PoRTB 7 2 1 PortB registers 7 3 PoRTC 7 3 1 PortC registers 7 4 PoRTD 7 4 1 PortD registers 7 5 PoRTE 7 5 1 PortE registers 8 BUZZER 8 1 BUZZER REGISTER 9 TIMER EVENT COUNTER 9 1 TIMER COUNTER REGISTERS 10 INTERRUPT CONTROLLER 10 1 INTERRUPT CONTROL REGISTERS o NNNN OF m O00 N 12 11 SUPPLY VOLTAGE LEVEL DETECTOR SVLD 25 12 SERIAL WRITE BUFFER SWB 12 1 SWB AUTOMATIC SEND MODE 12 2 SWB INTERACTIVE SEND MODE 13 STROBE RESET OUTPUT 1
169. ial reset on Power On POR 32kHz output possible on the STB RST pin External reset pin 15 stage system clock divider down to 1 Hz Watchdog timer time out reset 3 interrupt requests 1Hz 8Hz 32Hz Oscillation detection watchdog reset Prescaler reset from 8kHz to 1Hz Reset with input combination on PortA 8 bit Timer Event Counter 4 Bit Input PortA 8 bit auto reload count down timer Direct input read 6 different clocks from prescaler Debounced or direct input selectable reg or event counter from the PA3 input Interrupt request on input s rising or falling edge selectable by parallel load register interrupt request when comes to 00 hex Pull down or Pull up selectable by metal mask Software test variables for conditional jumps input for the event counter Q Supply Voltage Level Detector Reset with input combination on PortA metal option 3 software selectable levels 1 3V 2 0V 2 3V or user defined between 1 3V and 3 0V 4 Bit Input Output PortB Busy flag during measure Separate input or output selection by register Active only on request during measurement to reduce Pull up Pull down or none selectable by metal mask if used as power consumption Input Buzzer output on PBO 24 pin PEO 28 pin Q Interrupt Controller 9 external interrupt sources 4 from PortA 4 from PortC 4 Bit Input Output PortC 8 internal interrupt sources prescaler timer and Ser
170. ical Wire Harness to GA GA End Effector Isometric View 178 6 1 3 Interface Teeth Detail Detail A Teeth Profile Detail B Teeth Top View 179 6 2 DR Stow Configuration In this picture we see the back of the DR It gives us a view of the grapple fixture with which we are going to interface with the GA As specified by the GA team we have tracking fixtures at 120 degrees to each other It also identifies the location of the power data connector 180 Here we see the front view and the stow fixtures to be used for stowing in the EM The high tolerance stow fixture designed to maximize capture envelope is to allow the GA to put us in the EM with imposing extra requirements on their GA Once the high tolerance fixture is in position it will be clamped down and positioned tightly and accurately and the other fixtures can then be locked in position There are 12 stow fixtures in total five support each arm one on the head and the high tolerance stow fixture at the base of the GF 181 Finally this is the configuration in which the DR is going to be stowed in its bay on the EM 182 6 3 Capture Envelope N GA CLEARANCE j ENVELOPE 75 ES GRAPPLE FIXTURE 12 i ABUTMENT PLATE 20 gt 50 et r S E e PAYLOAD 4 DIA MOUNTNG SURFACE 84 0 DIA GUARANTEED CAPTURE ZONE PR BE A 15 TO AXIS OF END EFFECTOR MAXIMUM MISALIGNMEN lt 10 ROLL
171. ics IK 52V 1 2 Inch CCD Camera 1 0 1 0 0 9 0 9 z 0 8 gt 0 8 e 07 gt 07 2 06 2 06 o 7 05 0 5 2 04 2 04 5 og 03 C 0 2 c 02 0 1 0 1 0 0 400 500 600 700 800 900 1000 400 500 600 700 800 900 1000 Wave Length nm Wave Length nm In Touch With Tomorrow TOSHIBA Toshiba America Information S ystems Inc Imaging S ystems Division 9740 Irvine Boulevard Irvine California 92618 1 949 461 4986 www cameras toshiba com 2003 Toshiba America Information Systems Inc In Touch with Tomorrow is a trademark of Toshiba America Information Systems Inc and or Toshiba Corporation ther products and names mentioned are the property of their respective owners specifications and availability are subject to change All rights reserved IK 253 3 03 Brushless DC Servomotors FAULHABER 109 Watt Electronic Commutation For combination with Gearheads 30 1 32 3 38 1 38 2 Encoders 5500 5540 Drive Electronics BLD 5608 BLD 5606 MCBL 2805 MCBL 3603 MCBL 5004 Series 3564 B 3564 3564 K 012B 024B 036 B 048 B 1 Nominal voltage 0 12 24 36 48 Volt 2 Terminal resistance phase phase 0 6 1 2 2 8 4 4 3 Output power P 109 101 101 101 W 4 Efficiency n 81 81 81 82 5 No load speed n 7 850 11 300 11 550 12 200 rpm 6 No load current with shaft
172. ide of the current state of the art 70 9 Conclusions This document has presented the operations systems controls electrical and mechanical design of a Dexterous Robot that meets the requirements set forth in MDR s request for proposal The robot performs at the required precision needed to perform the difficult task of WFC insertion and has the mobility and dexterity needed to complete all the servicing tasks It is small enough and light enough to be transported economically to the HST and can be powered and controlled effectively 9 1 Possible Improvements The obvious area for improvement in this design is the application of more time and resources to the analysis of the various systems so that the many approximations can be improved and more exact performance parameters could be determined With more time and specialized engineering experience the details of the design would be optimized and improved to a far greater extent than was possible in the time allocated for this project In particular nobody on our team had a substantial electrical engineering background which made the electrical computer and software portions of the design much more challenging We found that the main constraint on the design was the distinction between Grapple Arm and Dexterous Robot which created the need for a more complicated DR than could do the job if the two systems were operationally and physically integrated into one design More wor
173. ide single fault tolerance for the de orbit mission 5 Ensure that Level I performance is not degraded by robotic servicing As stated in MDR s request for proposal RFP 1 requirements 2 3 4 and 5 form the mission objectives for the Dexterous Robot DR system Additionally the DR will operate cooperatively with the Grapple Arm GA which provides a platform from which the DR will perform the servicing tasks The design described within this document has the necessary operations policies systems architecture control systems electrical power supply and mechanical design to achieve the above mission and to satisfy all the necessary requirements The DR is able to perform all necessary work within worksites on the HST with an arm span of 4 8 m 2 4 m per arm and 6 degrees of freedom in each arm It will be moved from work site to work site on board the end effector of the GA A general purpose manipulator arm is used to handle cables doors and other fixures on the HST A tool arm uses interchangeable specialized tools for tasks such as unscrewing driving latches and mating connectors The DR will achieve better than required performance through the use of autonomous abilities such as work site registration and active force control The DR will compensate for perturbations during motions which are due to the flexibility of the combined DR GA structure For reliability the DR has a fully manual backup mode and has been designed to a
174. iguration To stow the body and the arm securely it has been decided that the joints need to be held securely to prevent pivoting The boom structure is a thin carbon composite tube while the joints are titanium having stow fixtures at the booms might cause fracture because the boom structure is thin Nine stow fixtures will be needed to have a fixed body Two at each wrist one at each elbow one at the head pivot and two for the body will be sufficient Drawings detailing the stowed configuration can be found in Appendix 8 1 The stow fixtures are to be released from a signal from the DR ground control team once the GA team has confirmed successful grapple and mating is done 8 3 Mechanical System Implementation 8 3 1 Tool Arm 8 3 1 1 Interfaces The tool arm will interface with all tools and manipulate the WF PC2 and WFC3 As well during stowage the arm will interface with the EM via three stow fixtures one in the elbow and two in the wrist 8 3 1 2 Requirements The requirements of the tool arm come from the specified functional requirements 1 The DR shall have closed loop accuracy of 0 16 2 The DR motor gear ratio will be sufficiently great to allow minimum input to stack up to required resolution Linearly retract WF PC II 7 5 in the plane of WF PC II The DR s tool actuator shall be capable of applying 50 ft Ib of torque Resolution accuracy of Force Moment at end effector shall be at least 2165 and at least 2ft Ib Sto
175. ill go wrong prevent the cause or the failure mode GA DR movement DR fails tool Damage to collides with HST by HST payload Note The two process steps and failure modes and effects above have different frequency and severity indexes However they have been grouped together because all of the causes listed on the right apply to all three of the failures In calculating the Risk Index a frequency of 8 and a severity of 9 wree used representing the highest combination in the set and therefore the worst case scenario Structural failure due to Design GA and DR to withstand loads overload greater than the anticipated maximum Electrical failure unintentional implement a double positive system for power to actuators activation Power alone will not cause activation Electrical failure no IDR to enter safe mode when there is a communication between GC comunication failure ie movement ceases and DR and GA untill further instruction Sensor failure loss of to enter safe mode when there is a feedback incorrect picture of sensor failure surroundings Largest risk index Command corruption DR implement a double positive system for activated inadvertantly activation Command corruption GA or DR will sense location during ops Warning Largest risk DR activated incorrectly given when proximity too close 5 Power failure joints not backdrivable effectively have brakes enaged when not
176. ion of the arrow When the north pole comes to the position to face the salient pole P1 the shutter which is coupled to the shaft will shade PT1 and PT2 will be exposed to the light and a current will flow through the transistor Tr2 When a current flows through the winding W2 and creates a south pole on salient pole P2 then the north pole in the rotor will revolve in the direction of the arrow and face the salient pole P2 At this moment the shutter shades PT2 and the phototransistor PT3 is exposed to the light These actions steer the current from the winding W2 to W3 Thus salient pole P2 is de energized while the salient pole P3 is energized and creates the south pole Hence the north pole on the rotor further travels from P2 to P3 without stopping By repeating such a switching action in sequence given in Fig 5 the permanent magnet rotor revolves continuously Phototransistors Phototransistors PT1 Light source Revolving shutter Motor shaft Revolving shutter Phototransistors Fig 4 Three phase unipolar driven brushless dc motor from Ref 1 p59 Fig 4 2 with winding directions swapped Page 12 3 48531 EMS Chapter 12 Brushless DC Motors 0 120 240 360 480 Revolving angle degree PT2 Phototransistors PT3 Output signals from phototransistors Winding currents S OQOCH Time Rotor positions Fig 5 X Switching sequence and rotation of stator s magnetic field from Ref 1
177. ity 1 2 3 4 5 6 7181 9 101111 12113 1 2 a 3 C 4 g 5 d 6 e 7 8 h 9 j 10 m 11 f 12 k 13 By adding the row and column number in quadrature 2 2 0 5 we can derive a single importance number for each requirement which serves as the basis for our final ranking C D E H G J B LF A M L K Hence our top ten software requirements are 1 The DR software shall have machine vision algorithms that will be able to match a xyz data from the LCS system and stereoscopic information from the video cameras with a 3d model 2 The DR software shall be capable of commanding the DR arms to any location and orientation and along any required trajectory and apply corrections accordingly based on vision system feedback 3 The DR software shall have the ability to solve multi degree of freedom movements to avoid collisions or critical occlusions with HST or the DR itself 4 The DR software shall have a situational awareness model that incorporates data from DR sensors ie motor encoders the DR vision system and internally stored data self knowledge 38 10 The DR software shall be sufficiently stable such that it does not crash or malfunction during servicing operations The DR software shall have a minimum level of autonomy such that it is able to detect a collision and take appropriate actions to prevent the following in order of priority 1 do no damage to the HST 2
178. k should be done in our overall tracking and proving of requirements Since the DR mission is of such a complex nature there is an enormous number of requirements which are interconnected Our present methods also limit the design as we were unable to perform proper mechanical analysis of the joints which would have allowed us to better assess performance Also we did not have the means to simulate all of the operations both manpower and computer power which would validate our Functional Flow or perhaps allow us to identify better operations concepts The most limiting specifications were those requiring accuracy and precision at the end effectors in order to achieve alignment of the WFC3 rails We proposed the shortening of one WFC rail to allow us to get the process started on one side first rather than having to simultaneously align two rails with tight tolerances What specifications are most limiting or where could they reasonably be modified or best clarified to simplify or improve the design 71 10 References 1 2 3 4 5 6 7 8 9 10 11 12 13 MDRobotics Request for Proposal 2004 Hubble Space Telescope HST Robotic Servicing Mission NASA Hubble Space Telescope Program HST Robotic Servicing Mission Concept Review May 13 14 2004 HST Project Science Office Spacecraft In Orbit http hstsci gsfc nasa gov orbit html January 2000 ANSI AIAA G 043 1992 Guide for the Prepa
179. ll achieve the following performance requirements during its operations 4 2 1 1 The DR shall be capable of maneuvering anywhere in the workspace 4 2 1 1 1 The DR shall have a range of motion such that it can move anywhere in the workspace with a resolution of 2 4mm translational and 0 1 rotational 4 2 1 1 2 The DR shall have reach and maneuverability TBD 4 2 1 2 DR shall have accuracy of 1 relative to commanded position 4 2 1 2 1 The DR shall have closed loop accuracy of 0 16 4 2 1 2 2 The DR shall have angle resolvers with tolerance stack up of less than 1 4 2 1 2 3 The DR motor and gearbox tolerance stack up shall be sufficiently small to satisfy the above These requirements will be affected by the accuracy of the GA 4 20 0 The DR shall perform the power augmentation procedure 4 2 2 1 The DR shall retrieve both DBA II connector interface plates V2 and V2 from the conduit 4 2 2 1 1 The DR End Effector shall grapple the DBA II Connector Interface Plate This is the process of removing the DBA II connector interface plate from its storage location on the conduit e The DBA II connector interface plate must meet the requirements for the DR tool arm End Effector Interface 4 2 2 1 2 The DR shall move the DBA II connector interface plate to its location on the Diode Box e DBA II connector interface plate assumptions Angle Aluminum 6 x3 x3 x1 8 mass of plate 200g mass of J8B and J6B connectors 100g each total mass
180. losed loop functions or are triggered by a task such as end effectors motion commands 5 7 1 Autonomy Requirements The autonomy laid out in the above section imposes a number of functional requirements on the DR These requirements are decomposed into performance specs in the relevant detailed design sections of this report The DR shall be capable of performing an Emergency Stop to ensure that the HST is not harmed o The DR shall be able to detect conditions requiring an emergency stop and halt all motion prior to a potential collision o The DR shall have sensors to detect whether there are any objects within an unsafe distance of the DR o All DR commands other than an operator override shall have a lower priority than Emergency Stop o DR shall and halt all motion within 10 6 mm and 0 4 Negotiated total stopping distance with GA o The DR CPU shall have a connection to the GA that allows it to signal when an emergency stop is required o The DR CPU shall signal to ground control that an emergency stop has occurred The DR shall have a backup mode allowing full manual control in the event of primary control systems failure Single Fault Tolerance o DR shall have a direct command link between GC and DR subsystems o GC shall have an explicit option to override the DR Emergency Stop The DR shall be capable of coordinated joint motion when controlling either of its arms o DR CPU shall be capable of doing 6 Degree of Freedom DOF i
181. m Table A8 1 Temperature limits of DR Operational mode Survival mode Power Fuses 10 to 20 15 to 35 C amp DH 20 to 70 40 to 85 Electronic components 20 to 65 50 to 70 Joint actuators 20 to 70 65 to 80 End effector actuators 20 to 70 65 to 80 Camera sensors 20 to 65 50 to 70 Structure 15 to 65 45 to 65 Temperatures are in C Internal heat generation 0 All electronics off ernal min With our 50 W power consumption requirement for actuators we can assume the robot has 40 efficiency hence the heat dissipated would be 0 6 50 30 W ernal max We can add to this active heating depending on our analysis and thermal control requirements Solar flux extremes Assumptions Dexterous robot when fully extended is assumed to be a cylinder with a 4 72 m length and a diameter of 0 2 meters This is used for the worst case steady state analysis for the energy balance a Solar absorptivity Full sun X 1353 x 4 72 x 0 2 1277 W Full shadow 9 W Albedo Extremes Distance to DR from earth makes DR view factor similar to a flat plate projected area of the DR cylinder onto the DR orbit Albedo factor is taken as 0 3 for hot case and 0 23 for cold case F 0 85 for hot case as assumed for flat plate and Earth gt DR arth DR of HST cloud in the way or other geometric variation amp 0 5 for cold case incase Surface ar
182. m 0 8 um 0 5 um 0 5 um 0 35 um Feature Size SRAMS Cell Design 6T 29 6T 28 6T 2R 6T 2R 6T 2R Redundancy te x1 8 W L 8 BL 16 W L 16 BL 16 W L 16 BL 32 W L 32 BL r n fro Read Write lt 55 nsec lt 30 nsec lt 25 nsec lt 30 nsec s a Q e Performance 33 nsec typical 19 nsec typical 19 nsec typical 19 nsec typical zeu noeg 64K to 4M Power O Post Rad 5 lt 10 mW lt 10 mW lt 10 mW lt 20 mW lt 10 mW Active 50 mW Hz 20 mW Hz 20 mW MHz 30 mW MHz 5 mW MHz 8 S Ity Package 36 FP 32 LCC 40 FP 32FP 40 FP Dual Chip 40 FP The 256K SRAM fabricated in our QML qualified 0 8 micrometer process offers 30 and 40ns access times with total dose dose rate upset and SEU characteristics identical to those of the 1M SRAM Packaging options for the 256K products include 36 lead flat pack 40 lead flat pack 28 pin Dual Inline Package DIP The Importance of QML Qualification BAE SYSTEMS in Manassas was the first producer of space qualified rad hard semiconductors to obtain QML qualified status This achievement attained after an extensive validation audit by a team of government and industry experts assures customers that quality management procedures processes and controls are in place from design through wafer fabrication and module packaging to final customer delivery BAE SYSTEMS is the only supplier to obtain 1 0 micromet
183. n close proximity to it Lack of Markers or Digital Landmarks The DR vision sensor will not have the benefit of special purpose markers attached to any of the HST components to aid in their identification and position orientation measurement The vision sensor s used must be able to provide enough information to the image processing software such that it is able to identify each DR and HST component and its position and orientation Certain vision sensors such as a single camera may have difficulty doing this and may require the use of a second camera to gain full depth information Current Technological Options There are two major DR vision sensor alternatives that will provide position xyz information e Traditional visual spectrum cameras e Laser based scanners Both of these technologies have been demonstrated in space applications with the former being extensively applied on both the Canadarm and Canadarm2 and the latter only in limited proof of concept tests on STS 105 The laser scanner was selected for the DR s main vision sensor The conventional camera technology is limited in that it requires a second camera to gain depth measurement without the aid of fudicials markers Space cameras also suffer from the effects of inconsistent lighting during orbital operations as a result of the ultra high contrast between light and shadow rendering the vision sensor information useless This would mean that despite being a fully proven technol
184. n concert with another robot the Grapple Arm which will serve as a mobile platform from which the DR will operate Power and communications will be provided to the DR from the systems in place on board the EM component of the HRV and the DR will be stowed on the EM when not in use 3 2 Mission Objectives 3 2 1 Power Augmentation The DR is responsible for connecting the power conduits to the V2 and V2 diode boxes This conduit connects the HST solar panels to the new batteries on board the de orbit module 3 2 2 Replace aging Rate Sensing Units RSUs The DR is responsible for installing new Rate Sensing Units RSUs to allow the HST to maintain pointing control when one of the remaining three RSUs fails This will be accomplished by installing the Wide Field Camera 3 WFC3 on which the new RSUs are mounted 3 2 3 Extend Scientific Life The repair of HST power and pointing systems will extend the scientifically useful life of the HST for a number of years Additionally the WFC3 will expand the capabilities of the HST further increasing the scientific value and potential of the Hubble Mission 3 2 4 Do No Harm to Hubble During all parts of the mission Level 1 performance of the HST must not be degraded The DR will operate so as to do no harm to the HST 3 3 Stakeholders Users The main user of the DR system is the NASA HST mission team This team requires a reliable and effective robotic servicing system to fulfill their mis
185. n eren 104 11 3 ROOT LOCUS PE OT m RE 106 11 4 ECCS 107 11 5 STEP INPUT RESPONSE 4 er det e tete eed ree e tives 108 11 6 CORRESPONDENCE WITH DR CHAD ENGLISH PHD 108 11 7 DATADICTIONARY ceitean RE 114 11 8 MINI SPECIFICATION FOR MOTOR CONTROL LEVEL 2 1 1 2 0000001000 0 0 115 APPENDIX THEE CT RICA D rnt deoeausttensstestesoasasescsbesiceonave 119 APPENDIX Poll CABLE GA VOUT abdidit deed 119 Appendix 7 4 1 Cable Layout Maps eso tee ederet etn 119 Appendix 7 1 2 Layout and Cabling 1 Lower Tool 120 Appendix 7 1 3 Layout and Cabling 2 Upper Tool 121 Appendix 7 1 4 Layout and Cabling 3 Lower Manipulator 122 Appendix 7 1 5 Layout and Cabling 4 Upper Manipulator 123 Appendix 7 1 6 Layout and Cabling 5 DR Body essent 124 Appendix 7 1 7 Layout and Cabling 6 125 APPENDIX 7 2 ELECTRICAL FUNCTIONAL BLOCK eee eee nnne 126 Appendix 2 1 High Leve EFBD ausi aet non ee der pere Eee 126 Appendix 2 2 T Motor EU ee eee e e ert eter te Eng 127 Appendix 7 2 3 2 Thermal Control System essere nennen eene 128 Appendix 7 2 4 EFBD 3 LCS EU Control Unit eee tert
186. n to resolver error was analyzed in various arm configurations to determine the expected resolution of the end effector Calculations are based on the resolvers selected which have a manufacturer quoted error of 4 arc minutes A MATLAB code which computes the end effector position as a function of joint angles and boom lengths was written and used to determine the error in tip position introduced by varying commanded inputs by the maximum error of 4 arc minutes Table 8 2 below outlines the results Note in this analysis X is in direction of shoulder roll joint Z is toward robot s head and Y is negative of XxZ See mmod rev4 mws for maple code used in this analysis Table 8 2 End Effector Resolutions See Appendix 8 6 for a complete tabulation of configurations considered the resultant errors and the maple code used This analysis was not performed to include all possible symmetries so the worst case for translation AX AY AZ and rotation AQ2 AQ3 are assumed to be the largest of each set as shown in Table 8 3 Table 8 3 End Effector Resolution Requirements Met Overall we expect the DR to have an end effector resolution better than the cited values since these are derived from analysis of cumulative worst case errors in resolver data However we do not have a quantitative result for more optimistic performance figures 8 3 2 Manipulator Arm 8 3 2 1 Interfaces The manipulator arm will be required to open
187. nation of the position and orientation of each object will be determined 43 GC comm link data Lighting System Video Camera gt on off data focus settings To Main Controller LCS Pan Tilt Motor comm link data Commands Les Pan Tilt motor data commands motor data commands data results of data requests commands data preprocessed tracking data XYZ data preprocessed full scan data tracking data LCS Full Scan LCS Tracking Figure 6 7 Vision System 44 6 4 4 Level 2 breakdown For reasons of brevity we have not developed every software module to the detail of a level two breakdown However as an example we do present level two breakdowns for both the motor controller and the thermal control modules 6 4 4 1 Level 2 example Motor Command Please see Figure 6 8 Force Torque Monitor This module will continuously loop over the Force torque sensor data and report processed data to the overload monitor the command interpretation module so that it may send the data to the GC and to the motor command calculator Overload Monitor Compares force torque data to overload values and signals the GC and the main controller if we exceed the specified safe limits or each joint Command Interpretation This module will take in all external commands to the motor controller module and interpre
188. nd Cabling 5 DR Body 124 RS SAN Appendix 7 1 7 Layout and Cabling 6 EM i SCANS zs SS Tu CU 55555555755 555555555 a 555555555555 ob nd 59 a 94895 q t E go jeu a Soy o a E o E c gt a coe oc oe gt lt SSeS Sea Se Sa eS SS eS x o 95 Qgsls wo 3 i58 Tr o 2 D 5 S NET E J X0 lt ESSD aea sna 1 DS 7 mat RMS 1 ab mot SSSSNSSN E coc Sna SS 5 6 lt 62 5 Rarer 1 1 Tem a 2 4 2 2 555555555555 MANN 5 gt RS SSE 2 E SNR 3 RAG SSN 2 65 a le 5 6551 voa T5 e 2 essi vea TY 11 1 1 1 NES at 1 E 1 a fee D a 94825 ij FLEEIS 1 5 t a 8 27 9 E 5 E Jr a rer ay 1 ct 5 SES o MS lt 5 ipM Gs 55 S 948 E t oon a Ss oz e S 8 Ti bdo 4 FI
189. nd is coupled to the output shaft Motor and gearbox details are found in Appendix 8 3 7 8 3 3 Body The body will be where all other parts interconnect The shoulders for the arms the head for the LCS the tool caddy and the GA power data interface will all be in the body The EM will also interface when stowing or releasing the body 8 3 4 Tools 8 3 4 1 Interfaces The tools carried on board are needed by the DR to perform certain tasks required by the customer These tasks require that tools can interface with 1 The tool end effector The blind mate connector 7 16 hex interface The A Latch 7 16 ex interface The bolt holding the ground strap in place The J9 and 1553 terminator plugs P6A P8A connectors Ground strap The conduit to harness to the handrail Qo cul ON Uv oC ah The end effector interface will be common to all tools to simplify the design The tools will have the end shown in Figure 8 4 for gripping which matches the end effector design discussed later 62 Figure 8 4 Tool EE interface 8 3 4 2 Tool Requirements The 7 16 tool will be 2 long to reach the blind mate connector The 7 16 tool will have a 7 16 hexagonal male interface The 7 16 tool will interface with the tool end effector on the DR The 7 16 tool will be able to turn the blind mate connector 5 turns The 7 16 tool will be able to turn the A latch 22 5 turns The ground strap release tool will have a 7 16 he
190. ne or exactly on the imaginary axis Moreover from the requirement that the HRV shall do no harm to the HST it is apparent that any overshoot of the desired position by the DR will not be tolerated In order to accomplish this the system must be critically or slightly over damped such that gt 1 6 1 5 6 Bandwidth We may need to compensate for small oscillations in the tip position as the result of vibrations in the GA and DR as whole therefore our bandwidth shall be able accommodate our highest predicted natural frequency 107Hz Appendix 8 contains the details of the modal analysis 6 2 Control Architecture 6 2 1 Control Philosophy Distributed controllers and Centralized Coordination Each controlled device will have its own micro controller that will handle all low level operations Conversely all command operations and advanced data handling will be accomplished by a centralized CPU In this dictator style control the central controller does not need to spend its processing power on low level monitoring operations Instead the CPU simply requests data from a device specific micro controller when required 6 2 2 Controlled Devices To achieve the functional and system specifications the following components need to be controlled 1 Arm motors to control the precision positioning of the end effector 2 LCS orientation motors to control the direction the LCS is pointing at 3 Control torque applied by end effector
191. ne to glare etc To what extent does this assumption hold can direct sunlight blind the LCS and is this the case for all surfaces this leads me to my next one 1 Since the LCS determines depth information by bouncing a laser off of an object how well does it perform on a highly specular surface such as the Hubble the exterior is as shiny as a mirror 2 Know the LCS has two modes operation scanning and tracking could you elaborate on the advantages and limitations of either mode Does tracking require pre placed targets or will well defined edges suffice 3 How fast can the LCS update its scan what resolutions are available since there are no markers on the Hubble we ll have to match each scan to a 3D model 4 How large Mb is each scan are you aware of any rad hard processors that can deal with that much information to provide useful feedback for a control loop our robotic arms 5 Has NepTec used the LCS to provide visual feedback to a control system how did you do this 6 Lets say had two LCS s operating at the same time side by side would they interfere with each other we re required to have single fault tolerance in our system etc we wouldn t necessarily run them at the same time but who knows 7 How do scientists in the machine vision field estimate the computational cost of 3d model matching or registration this is the one that we re really struggling with since we need to select a processor
192. ng blind mate connector 5 3 2 5 3 Drive tool until connector is released 5 turns 5 3 2 6 Release A Latch 5 3 2 6 1 Position 7 16 counterclockwise ratchet tool for driving A Latch 5 3 1 6 2 Drive tool until A Latch is released 22 5 Turns 5 3 1 6 3 Stow 7 16 counterclockwise ratchet tool in caddy 5 3 2 7 Grapple Interface Plate with Tool Arm 5 3 2 8 Retract WF PC2 7 5 from HST 5 3 2 6 1 DR withdraw WF PC2 from bay on HST 5 3 2 6 2 DR maneuver WF PC2 to safe distance from HST 5 3 2 9 Stow WF PC2 at temporary stow position 5 3 2 7 1 DR GA move to DR stow site while carrying WF PC2 5 3 2 7 2 Insert WF PC2 in temporary stow fixture 5 3 2 7 3 Release WF PC2 5 3 2 10 DR standby 5 3 2 11 GA standby 5 3 3 WFC3 installation 5 3 3 1 Activate GA 5 3 3 2 Activate DR 5 3 3 3 Retract thermal contaminant cover 5 3 3 4 Stow cover on EM 5 3 3 5 Release ground strap from EM As above with 7 16 clockwise ratchet tool 5 3 3 6 Release A latch As above with 7 16 clockwise ratchet tool 5 3 3 7 Grapple WFC3 with Tool Arm As above 5 3 3 8 Retract WFC3 7 5 from EM As above 5 3 3 9 DR GA move to HST WFC site while carrying WFC3 5 3 3 10 DR Stabilize WFC3 5 3 3 11 Position WFC3 for insertion into HST 5 3 3 11 1 Align longer rail using video from manipulator arm 5 3 3 11 2 Engage longer rail insert a bit 5 3 3 11 3 Align shorter rail using video from manipulator arm 5 3 3 11 4 Engage shorter rail insert a bit 5 3 3 12 Push
193. ns Packaging is available for the 1M SRAMs in 40 lead flat packs 256K pin compatible and 32 lead flat packs 1x10rad Si sec latchup immunity and a tested Single Event Upset SEU rate of less than 1x10 errors bit day This product offers the highest density radiation hardened SRAM without compromising cycle performance Our 2M SRAM offering utilizes two 1M die in a dual package to achieve the best size volume and power in the industry Currently under development the 4M SRAM is the 1M SRAM fabricated in our 0 5 micrometer CMOS technology Feature enhancements provide an L of 0 35 micrometers The configuration is 512K x 8 and is offered in 40 lead flat packs compatible with Packaging is available for Organization Operation Asynchronous Asynchronous 32K x 8 256K 1M 30ns 40ns 60ns 25ns 30ns 40ns 1M x 1 256K x 4 128K x 8 Asynchronous 256K x 8 128K x 16 Asynchronous 4M 512K x 8 Asynchronous flat packs 256K pin compatible and 32 lead flat packs Our 50V 10 50V 1096 5 0 V 10 3 3 V Ar Power Supply 5 0 V 10 9 33 gt 5 3 3 V 5 EKO MEER 2 5 V 40 2 5 V 40 ae rad latior VO CMOS or TTL CMOS or TTL CMOS or TTL CMOS or TTL CMOS or TTL Bulk CMOS Bulk CMOS Bulk CMOS Bulk CMOS Bulk CMOS h d d EPI ar n e Minimum 1 0 u
194. nse times listed below are approximate Styles 1 amp 2 Have perforated probe tips for measuring ambient air temperatures Style 2 has a brass clip to secure probe to a surface Max Probe Type Probe Response Cable Temp Range Lg Time sec Temp Styles 3 6 Have bendable stems that adjust to area being tested Designed to measure air temperatures and for immersing into liquids Styles 7 9 Have bare tips for measuring ambient air temperatures and flat surface temperatures Max Probe Type Probe Response Cable Temp Range Lg Time sec Temp Each 1 Type 302 SS Probes dia Pw 4 ft Coiled PVC Cable J 40 to 4500 F 4 10 176 F 3868K42 K 40 to 4500 F 4 176 F 3868K43 47 T 40 to 500 176 3868 44 47 85 2 Type 302 SS Probes dia with 46 Fiberglass Cable 40 to 896 3868K641 47 85 K 40 to 896 F ee 2 47 85 40 to 896 2 3868K643 47 85 3 Type 316 SS Probes dia oun Cable J 432 to 39095K61 15 10 J 32 to 1400 39095K62 16 20 32 to 1400 39095K63 17 30 J 32 to 41400 39095K241 19 50 K 432 to 41600 F 39095K64 15 10 432 to 41600 39095K65 16 20 K 432 to 41600 F 39095K66 17 30 32 to 41600 39095K242 19 50 328 to 700
195. ntrollers These requirements however do not necessarily contribute the most to its complexity difficulty of implementation or to the demands it places on other systems As a result two lists of requirements have been produced the first ranked in order of fundamental functionality and the second in terms of the complexity induced by the requirement These two lists can be combined in a matrix format whereby we will be able to correctly rank each requirement based on both its core functionality and complexity factor The various requirements not in any particular order are stated below a The DR software shall be capable of accessing the communications system on the EM and communicating with ground control The DR software shall be capable of operating all actuators and devices on the DR c The DR software shall use a vision system to locate all elements of the workspace including their orientations and positions relative to the DR d The DR software shall be capable of commanding the DR arms to any location and orientation and along any required trajectory and apply corrections accordingly based on vision system feedback e The DR software shall have the ability to solve multi degree of freedom movements to avoid collisions or critical occlusions with HST or the DR itself f The DR software shall complete machine vision processing tasks in a timely fashion such that it does not unduly prolong servicing operations g The DR software shall be
196. nverse kinematics to solve joint angle changes to achieve commanded EE locations o DR shall be capable of simultaneously powering and commanding all 6 joint motors in one arm o DR shall be able to command its motors at a continuous range of speeds from zero up to the maximum speed of a given joint o Motor commands shall have a lower priority than Emergency Stop The DR shall be capable of moving its end effector along a constrained path while applying a force as during the insertion of the WFC o DR CPU shall be capable of doing the 6 Degree of Freedom DOF inverse kinematics and joint rate adjustments required to solve joint motions for a constrained end effector path The DR shall use active force control to limit off axis forces to prevent jamming of the WFC o DR shall stop motions if forces at the end effector exceed limits set by the operators TBD 24 o DR Shall have a force and torque sensor at each end effector capable of metering 200 of the expected forces and torques o DR Shall use active force control to limit off axis forces to 10 Ibs e The DR shall use a vision system to correct user commands for perturbations due to GA DR structural flexibility o DR shall have a vision system to provide accurate position info WRT work site o DR shall use a model matching algorithm to compute its delta vector distance from actual DR position to reference DR position used in operator commands e The DR shall report telemetry s
197. o 4 0 mm W 0 206 0 189 0 131 0 109 A 7 Stall torque M 41 2 5215 53 56 8 oz in 8 Friction torque static C 0 156 0 156 0 156 0 156 oz in 9 Friction torque dynamic e 3 4 105 3 4 103 3 4 103 3 4 105 oz in rpm 10 Speed constant k 658 475 324 258 rpm V 11 Back EMF constant 1 521 2 107 3 089 3 877 mV rpm 12 Torque constant ky 2 06 2 85 4 18 5 24 oz in A 13 Current constant k 0 49 0 35 0 24 0 19 A oz in 14 Slope of n M curve An AM 191 219 219 219 rpm oz in 15 Terminal inductance phase phase L 96 194 427 678 uH 16 Mechanical time constant T 10 11 11 11 ms 17 Rotor inertia J 4 81 10 4 81 104 4 81 10 4 81 104 oz in sec 18 Angular acceleration 86 109 111 118 10 rad s 19 Thermal resistance Rint Rina 2 5 6 3 C W 20 Thermal time constant srg ll Boy S 21 Operating temperature range 30 to 125 22 to 257 C F 22 Shaft bearings ball bearings preloaded 23 Shaft load max radial at 3 000 20 000 rpm 7 4 mm 0 291 in from mounting flange 389 263 oz axial at 3 000 20 000 rpm push on only 180 108 02 axial at standstill push on only 472 oz 24 Shaft play radial E 0 015 0 0006 mm in axial 0 mm in 25 Housing material aluminum black anodized 26 Weight 10 9 oz 27 Direction of rotation electronically reversible Recommended values 28 Speed up to Ne max 27 000 27 000 27 000 27 000 rpm 29 Torque up to Me max 6 67 6 23 6 22 6 23 oz in 30 Current up to 22 le max 3 68 2 50 1 71 1 36 A at
198. odulus Flexural Yield Strength Compressive Yield Strength Compressive Modulus Shear Strength Thermal Properties CTE linear 20 C Heat Capacity Thermal Conductivity Metric 1 26 1 8 g cc 60 65 64 19 2100 MPa 13 520 GPa 6 41 38 GPa 110 380 MPa 110 1720 MPa 11 15 GPa 30 120 MPa 9 14 um m C 1 1 2 J g C 6 400 W m K English 0 0455 0 065 Ib in 60 65 9310 305000 psi 1890 75400 ksi 930 5510 ksi 16000 55100 psi 16000 249000 psi 1600 2180 ksi 4350 17400 psi 5 7 78 yin in F 0 239 0 287 BTU Ib F 41 6 2780 BTU in hr ft F Comments Average 1 57 g cc Grade Count 11 Average 63 3 Grade Count 3 Average 810 MPa Grade Count 11 Average 190 GPa Grade Count 10 Average 17 1 GPa Grade Count 5 Average 200 MPa Grade Count 5 Average 530 MPa Grade Count 1 1 Average 12 3 GPa Grade Count 3 Average 64 3 MPa Grade Count 7 Average 12 Grade Count 4 Average 1 1 J g K Grade Count 3 Average 110 W m K Grade Count 9 http matweb com search SpecificMaterial asp bassnumzO1780 Subcategory 7000 Series Aluminum Alloy Aluminum Alloy Metal Nonferrous Metal Close Analogs Composition Notes Composition for AA 7075 not Alclad 7075 specifically Aluminum content reported is calculated as remainder Composition information provided by the Aluminum Association and is not for design Key Words
199. oelectronic Marin SA www emmicroelectronic com Figure 3 Typical Configuration Vpp 1 4V up to 3 3V EM6607 V Regulator SLEEP 52 1 Oscillator ss PE Reset Strb Rst oe Test Figure 4 Typical Configuration Vpp 1 2V up to 1 8V DD VREG Oscillator SS PE Reset Strb Rst Test 06 04 Rev B Copyright 2004 EM Microelectronic Marin SA 6 www emmicroelectronic com EM6607 2 Operating modes The EM6607 has two low power dissipation modes STANDBY and SLEEP Figure 5 is a transition diagram for these modes 21 Active Mode The active mode is the actual CPU running mode Instructions are read from the internal ROM and executed by the CPU Leaving active mode via the halt instruction to go into standby mode the Sleep bit write to go into Sleep mode or a reset from port A to go into reset mode 2 2 STANDBY Mode Executing a HALT instruction puts the EM6607 into STANDBY mode The voltage regulator oscillator Watchdog timer interrupts and timer event counter are operating However the CPU stops since the clock related to instruction execution stops Registers RAM and I O pins retain their states prior to STANDBY mode A RESET or an Interrupt request cancel STANDBY mode 2 3 SLEEP MODE Writing the SLEEP bit in the register puts
200. ogy RSS operations would have to be dependent on lighting conditions introducing an element of unreliability that is not acceptable Laser based scanners are a new technology that was first developed for aerial surveying tasks and has been recently introduced into space operations They have the advantage of being almost completely immune to the lighting effects of the sun and are also capable of operating in complete darkness given that the sun appears to rise and set 16 times a day in LEO this is essential for long duration servicing operations The accuracies quoted for laser scanners are also comparable to the photogrammetric results obtained using a conventional camera with special target markers 9 There are two laser based vision sensors that have been designed for the space environment NepTec s LCS Figure 6 3 and MDR Optech s RELAVIS Figure 6 4 RELAVIS is intended to work at extremely long ranges so that it would be useful for rendezvous operations and LCS has been design for shorter range use and is currently being considered to inspect tiles for the OBSS project see Table 6 1 for RELAVIS and LCS comparison Because NepTec s product is already partially adapted to the DR s needs it was selected as the primary vision sensor 34 Figure 6 4 MDR OpTech RELAVIS 35 Instrument Parameter Feature RELAVIS Goals NepTec LCS Flight Tested no Yes Primary Laser 3D auto synch Technology Optech
201. om 12 413 Wrist Fairing 2 991 Joint Structure 28 800 Thermal Protection Blankets 1 173 Motor Electronics i 1 440 Heaters 1 540 Collision Avoidance System IR emitter CQX 19 0 147 IR detector j 0 147 Tool Arm total 105 804 kg Manipulator Arm PIE Margin Allocated Mass kg 09 Brushless Motor Faulharber 3564 024 B 1 9467 Worm Gearbox FaulHarber G2 6 2 835 Secondary Planetary Gearbox Faulharber 30 1 1 482396 300 P 1 7892 Toshiba IK 52V 0 0945 3 707 2 112 Shoulder Fairing 10 87145 Upper Boom 16 55239 Lower Boom 8 517952 Wrist Fairing 1 27086 Joint Structure 21 6 Thermal Protection Blankets 1 23 452 Motor Electronics 1 44 Heaters 1 54 Collision Avoidance System IR emitter CQX 19 1 0 147 IR detector 0 147 Manipulator Arm total 99 50545 kg 165 Body Laser Camera System LCS Pan and Tilt motors Worm Gearbox Secondary Gearbox kkk Motor Electronics Heaters Collision Avoidance System Thermal Protection System Structure Mass Budget Summary sub total margin Number Design MaMargin Allocated Mass kg 0 704 1 144 25 41 1 9467 0 945 0 494132 0 5964 8 58 0 66 0 66 0 66 0 66 0 48 0 88 0 0315 0 0315 4 294668 55 Body Mass Total 43 88323 NepTec LCS Faulharber 3564 024 B FaulHarber G2 6 Faulharber 30 1 Harowe BRCT 300 P General Purpose Cli
202. om caddy 5 2 3 3 5 Move Tool Arm End Effector into position inside diode box 5 2 3 3 6 Remove P8A connector from diode box 5 2 3 3 7 Connect P8A connector to interface plate 5 2 3 3 8 Repeat P8A ops for P6A connector 5 2 3 3 9 Stow right angle tool in caddy 5 2 3 3 10 Stow any remaining fixtures 5 2 3 3 11 Close diode box V2 5 2 3 3 12 DR standby 5 2 3 3 13 GA standby 5 3 WFC3 Operations 5 3 1 Remove Ground Strap 5 3 1 1 Activate GA 5 3 1 2 Activate DR 5 3 1 3 Move GA DR to Work Site at WF PC2 5 3 1 4 Release Ground Strap 5 3 1 4 1 Grab hold of GS with manipulator hand 5 3 1 4 2 Acquire ground strap tool from caddy 5 3 1 4 3 Use ground strap tool and release ground strap by loosening bolt 5 3 1 4 4 Put away ground strap tool 5 3 1 5 Temporarily Stow Ground Strap 5 3 1 5 1 Use Manipulator arm to position ground strap over rail 5 3 1 5 2 Acquire a clip tool from tool caddy 5 3 1 5 3 Attach GS to rail using clip tool 5 3 1 5 4 Release GS from manipulator arm 5 3 1 8 DR standby 5 3 1 9 GA standby 5 3 2 Remove and Temporarily Stow WF PC2 5 3 2 1 Activate GA 5 3 2 2 Activate DR 77 5 3 2 3 Move GA DR to Work Site at WF PC2 5 3 2 4 Install WF PC2 interface plate 5 3 2 4 1 Acquire interface plate 5 3 2 4 2 Position interface plate with guide studs 5 3 2 4 3 Place interface plate 5 3 2 5 Release blind mate connector on WF PC2 5 3 2 5 1 Acquire 7 l6 counterclockwise ratchet tool from tool caddy 5 3 2 5 2 Position tool for drivi
203. ometry will be sufficient for all other tasks 145 Appendix 8 3 Calculations Appendix 8 3 1 Tool Manipulator Arm Calculations Basic Parameters Main Boom Lengths Arm Diameter Arm Offset Appprox Arm Length Tip Speed with 100016 mass Tip Rotation Assumptions Stop 100015 Case Apply 50 ftlb Torque Case move 100016 Factors of Safety Static Margin Kinetic Margin Inertial self weight Forces on Arm neglected Assumed small compared to end effector loads Tip Speeds adjusted to make Power draw reasonable TA Self Mass 105 8044 kg From Mass Budget EE Payload 1000 Ib 453 5924 kg Effective Payload Mass 506 4946237 kg Payload plus half of self mass Payload Moment of 210 9845 Assumes mass is the size of WfC3 which is Payload Kinetic Energy 0 405196 J approximated by a 82 x 90 x 32 rectangle Payload Rotational Energy 0 128539 J torqued about the Ixx axis Stopping Distance 0 008 m Stopping Angle 0 007 rad Tip Force F KE distance StaticMargin KineticMargin 99 31267 N Tip Torque T RE angle StaticMargin KineticMargin 37 76795 Nm This load case is less than the 50Nm requirement therefore is not Shoulder Torque Normal Tip Load dominating Required Torque T Length TipForce Required Torque 258 Nm Required Power 9W Elbow Torque Normal Tip Load Required Torque T Length 2 TipForce Required Torque 129 Nm Required Power 5 W Wrist Torque Normal Tip Load Required Torque T WristLength TipF
204. ontrol to DR Ground Control wiccccccccccscccccccccccscsssececcccccssseccesccesssssussseccccessuusaececsesesauaens 175 ICDi REFERENCES TTE 176 8 555 ia 177 6 1 GA END EFFECTOR QN 177 6 1 1 177 6 1 2 I LITANIAE 178 64 95 Interface Teeth Detail eie titer riter iere shes seh Hae Poe aeri RE 179 6 2 DR STOW CONFIGURATION cccsessscecececsesessssecececeeseseseseecceesesaaeceeececseaaeeeeceseceeaaeeeeececeesnsaeeeeececeeneaaeas 180 6 3 CAPTURE ENVELOPE ssssecsccocecsssscscccececsensnsncceececsenseseeesececesnseenaesecsceesseenaeecesceenseneaeeecscsesssneaeeeesceessnneeees 183 6 4 LOAD CALCULATIONS 184 6 5 CABLE MASS 8 2 1 121 2 0000 2000000000000000000000 184 6 6 ELECTRICAL INTERFACE 5 2 2 1412 0 00 0000000000000000000 185 6 6 1 s eie ierit RE n retinet e ARP E REC eee 185 6 6 2 Dat Interface zii esie Rt DR ER ENTIRE POUR PRENNE 185 APPENDIX 11 5 187 1 This page intentionally left blank 2 Abbreviations Abbreviation Definition AFC Activ
205. orce Required Torque 89 3814 Nm Required Power 3 Ww EE Torque 50 ft lb 67 7909 Nm Required Joint Torque T EETorque StaticMargin DynamicMargin Required Joint Torque 136 Nm Required Power 5 W tip acceleration 0 02 m s 2 EE Payload 1000 Ib 453 5924 kg Assumes mass is the size of WfC3 which is Tip Force F ma approximated by a 82 x 90 x 32 rectangle 9 071848 N torqued about the Ixx axis 146 Appendix 8 3 2 Tool Manipulator Joints Calculations TOOL ARM JOINTS Dominant Load Cases Joint Torque Shoulder Mass Budget mass 4 0 03 Torque Estimated Motor Mass Qty Total Shoulder 11 7 kg 4 47 0 kg Elbow 8 1 kg 2 16 1 kg Wrist 8 1 kg 6 48 4 kg Total Mass of Joints 111 5 kg Structure Estimated Boom Mass Qty Shoulder Same as upper boom 3 4 kg Upper Boom 15 8 kg Lower Boom 8 6 kg Wrist 0 9 kg Total Mass of Arm Structure 147 Appendix 8 3 3 Tool Manipulator Material Selection Material Properties Name Composite BendingStress 1 75 114285714 3 Pa 433714285 7 Pa 55142857 14 Pa Density 1570 kg m 3 4700 kg m 3 2700 kg m 3 1 90E 11 Pa 1 1E 11 Pa 7 10E 10 Pa Minimum strength for Bending minimum Bending Moment Radius Bending stress capability Segment Upper Boom Lower Boom Wrist Aluminium 3 51E 07 1 84E 07 1 84E 07 Titanium 4 47E 08 2 34E 08 2 34E 08 I carbon 1 69E 07 8 90E 08 8 90E 08 t carbon 0 0001 0 0001 1 0 0001 1 Radius 0 075 0 075 0 075 Minimum
206. outlined in detail in 1 Appendix 2 In case of failure the general operating scenario is defined as follows DR automatically enters safe mode DR resets systems DR performs safety and operational self tests If problem successfully eliminated then return to nominal operations If unsuccessful DR awaits further instructions from GC GC identifies solution Solution is implemented DR performs safety and operational self tests Nominal operations resume ST ON ie pe The operations procedures used to mitigate a set of specific failures characteristic of the potential operational disruptions are discussed in Appendix 1 2 Mechanical failure of the 7 16 tool Appendix 1 2 1 Failure of the main power system Appendix 1 2 2 Communications black out due to solar interruptions Appendix 1 2 3 18 5 5 2 Failure Modes and Effects Analysis In response to the mission requirement that the DR do no harm to the Hubble Space Telescope we performed Failure Modes and Effects Analysis FMEA on the operations performed by the DR The table shown in Appendix 4 illustrates this analysis as broken down into the following steps 5 5 2 1 Hazard ldentification First we identified the various categories of maneuvers performed by the DR For each of these actions a frequency index was assigned based on the scale given in Appendix 4 1 We then identified the key input and how damage will be caused to the HST Following this the failure mod
207. ovide the necessary torques to the tools however its range of motion is limited to 180 due to the cables In order to accomplish the multiple turns needed to operate the blind mate connector and A latch the 7 16 hex tool will be ratchet style allowing the wrist to apply multiple turns of 360 without removing the tool 8 3 4 3 1 7 16 Hex Tool 63 The 7 16 hex tool is used for the blind mate connector and the A latch Figure 8 5 below shows the basic tool design A ratchet style tool will be used as discussed above Both a right hand and left hand tool will be required in order to enable clockwise and counter clockwise torques Figure 8 5 7 16 Hex Tool 8 3 4 3 2 Ground Strap Tool The ground strap tool is used to torque the bolt holding the ground strap in place The design is shown in Figure 8 6 A circular end shape was chosen to maximize the area while remaining 1 25 in diameter The 7 16 female connector was filleted at the opening to facilitate its placement on the ground strap bolt Also the tool uses the common interface identified above Figure 8 6 Ground Strap Tool 8 3 4 3 3 RSU Tool The RSU tool manipulates the J9 and 1553 terminator plugs Figure 8 7 RSU Tool 64 8 3 4 3 4 Right Angle Tool Figure 8 8 shows the right angle tool design The shape was chosen to encompass the terminator plug holding it with pressure during movement The tool uses the connector wing tabs as a means of applying
208. p Clockwise 7 16 Ratchet Tool Right Angle Tool RSU tool Counter Clockwise 7 16 Ratchet Tq IR emitter CQX 19 IR detector FHA gt NNNNOANNON gt gt 249 193 Notes 10 exact mass talk about backup tools in case of loss Total Design kg 274 1124433 sized from terrestrial boards with comparable functionality A 0 kilo based on reasonable estimate mass of blankets calculated to be 0 1967 Kg M 2 take fiv _6096x0 508x1 5 dimensions of DR box Thermal Protection Calculations surface area total Mass of single TPS layer kg m 2 layers needed surface area total layers needed Mass of single TPS layer kg m 2 166 Appendix 9 Data Sheets 167 The Theta F T transducer The transducer is made of hardened stainless steel and the standard mounting adapter is made of high strength stainless steel Fx Fy b We have been using the ATI F T for automotive seat testing since 1998 We are impressed with its ruggedness and reliability Kevin Moore Automotive Testing Technologies BENEFITS AND FEATURES Extremely High Strength Precision machined from high strength stainless steel Overload pin stops make this an especially rugged transducer Maximum allowable overload values are 6 1 to 20 times rated capacities High Signal to Noise Ratio Silicon strain gauges provide a signal 75 times stronger than conventional foil gauges This signal is amplified
209. p60 Fig 4 3 2 Bipolar drive When a three phase brushless motor is driven by a three phase bridge circuit the efficiency which is the ratio of the mechanical output power to the electrical input power is the highest since in this drive an alternating current flows through each winding as an ac motor This drive is often referred to as bipolar drive Here bipolar means that a winding is alternatively energised in the south and north poles We shall now survey the principle of the three phase bridge circuit of Fig 6 Here too we use the optical method for detecting the rotor position six phototransistors are placed on the end plate at equal intervals Since a shutter is coupled to the shaft these photo elements are exposed in sequence to the light emitted from a lamp placed in the left of the figure Now the problem is the relation between the ON OFF state of the transistors and the light detecting phototransistors The simplest relation is set when the logic sequencer is arranged in such a way that when a phototransistor marked with a certain number is exposed to light the transistor of the same number turns ON Fig 6 shows that electrical currents flow through Trl Tr4 and Tr5 and terminals U and W have the battery voltage while terminal V has zero potential In this state a current will flow from terminal U to V and another current from W to V as illustrated in Fig 7 We may assume that the solid arrows in this figure indicat
210. peed for continuous operation Backlash at no load Bearings on output shaft Shaft load max radial 15 mm 0 591 in from mounting face axial Shaft press fit force max Shaft play on bearing output radial axial Operating temperature range metal steel 4 000 lt 12 ball bearings 34 Ib lt 34 Ib lt 45 Ib lt 0 0006 in 0 006 in 30 to 100 C 22 to 212 F length with motor output torque reduction ratio weight length 2444 S 23428 3056 K 2657 W 3564 continuous direction efficiency nominal without without 2642 W 3557 operation operation of rotation motor motor reversible L2 L1 L1 L1 L1 1 02 mm mm in mm in mm in Ib in Ib in 96 8 71 1 3 8 27 1 1 07 71 1 2 80 69 1 2 72 84 5 3 33 85 5 3 37 92 5 3 64 13 27 88 14 1 4 9 35 1 1 38 79 1 3 11 77 1 3 04 92 5 3 64 93 5 3 68 100 5 3 96 3 40 4 53 80 43 1 6 0 43 1 1 70 87 1 3 43 85 1 3 35 100 6 3 96 101 6 4 00 108 6 4 28 11 40 14 53 70 66 1 6 0 43 1 1 70 87 1 3 43 85 1 3 35 100 6 3 96 101 6 4 00 108 6 4 28 16 40 21 53 70 134 1 72 51 2 2 02 95 2 3 75 93 2 3 67 108 6 4 28 109 6 4 31 116 6 4 59 31 40 40 53 60 1890 51 7 2 51 2 2 02 95 2 3 75 93 2 3 67 108 6 4 28 109 6 4 31 116 6 4 59 40 40 53 53 60 246 1 7 2 512
211. ponse and excellent controlability Long lasting Easy maintenance usually no maintenance required Winding connections Ring connection The simplest A connection connection The highest grade A or Y connected three phase Normal Y connected three phase winding with grounded neutral point or four phase connection The simplest Two phase connection Mechanical contact between brushes and commutator Automatically detected by brushes etc Commutation method transistors Detecting method of rotor s position Reversing method By a reverse of terminal voltage Electronic switching using Hall element optical encoder Rearranging logic sequencer Page 12 2 48531 EMS Chapter 12 Brushless DC Motors Drive circuits 1 Unipolar drive Fig 4 illustrates a simple three phase unipolar operated motor that uses optical sensors phototransistors as position detectors Three phototransistors PT1 PT2 and PT3 are placed on the end plate at 120 intervals and are exposed to light in sequence through a revolving shutter coupled to the motor shaft As shown in Fig 4 the north pole of the rotor now faces the salient pole P2 of the stator and the phototransistor PT1 detects the light and turns transistor Tr1 on In this state the south pole which is created at the salient pole by the electrical current flowing through the winding W1 is attracting the north pole of the rotor to move it in the direct
212. pot in a raster pattern and making a range image where each pixel of the scan would have an X Y Z and intensity value Tracking was the original intent of the scanner and it worked on circular targets either normal SVS targets or retro reflectors I m not sure what I d say about advantages of either they did what they were designed to do Since then we ve developed algorithms for tracking generic objects without targets All it needs is some 3D detail like curvature Flat surfaces are harder to track although we can get most of their degrees of freedom just not the roll We also have modes of scanning in various scanning patterns Since LCS uses scanning mirrors we don t have to scan in raster patterns We can scan in essentially arbitrary patterns at gather 3D data at each point This has big benefits over other approaches because raster scanning like most 3D scanners gathers data in FOV of the scanner or some section of the FOV If we only want to scan certain objects or features on an object then everyone ends up throwing away most of the data and only keeping the relevant data Arbitrary scan patterns allow the scanner to only scan the points of interest especially given the ability to track where the object and features are 3 How fast can the LCS update its scan what resolutions are available since there are no markers on the Hubble we ll have to match each scan to a 3D model The update rate depend
213. purpose of our survival system is to ensure that the DR is not damaged or rendered inoperable during launch or operational phase This system includes thermal control and fault monitoring The heating system uses thermocouples located at thermally sensitive locations to determine whether active heating is necessary Unless active heating is necessary the temperature is maintained using passive heating and cooling The heating element will be Kapton heaters see Appendix 8 5 and to prevent over cooling MLI insulation blankets will be used Since the DR has to be single fault tolerant most vulnerable systems are duplicated and the survival system will detect failure to any of these components and switch to the backup Such systems include the electrical cabling data bus lights mini cams motor winding and others Other sensing capabilities We decided to provide the DR with two other sensing capabilities that are 1 IR sensors The IR sensors are located in specific locations on the DR that are not in the field of view of the LCS or the mini cams The purpose is to detect if those parts are too close to the Hubble 2 We will also use touch pressure sensor in the tool caddy to register whether the tools are in position When the tool arm acquires the tool it applies a pressure that stimulates the release of the right tool Control system The control system of the DR is comprised of the various sensors that report telemetry to the C amp DH where sof
214. py or hard disk drives However brushless dc motors which are smaller and more efficient have been developed for this application and have contributed to miniaturization and increase in memory capacity in computer systems Table 3 compares a typical ac synchronous motor with a brushless dc motor when they are used as the spindle motor in an 8 inch hard disk drive As is obvious from the table the brushless dc motor is far superior to the ac synchronous motor Although the brushless dc motor is a little complicated structurally because of the Hall elements or ICs mounted on the stator and its circuit costs the merits of the brushless dc motor far outweigh the drawbacks Table 3 Comparison of an ac synchronous motor and a brushless dc motor for an 8 inch hard disk drive AC synchronous motor Brushless DC motor Power supply direct current Inverter required Direct current low voltage low voltage for extension 12 24 V and interchangeability Speed adjustment Since speed depends on Adjustable independent of the frequency regional frequency adaptability is low Adjustment of starting time Adjustment not possible Adjustment possible Temperature rise High Low Efficiency Low approx 30 per cent High 40 50 per cent Output to volume ratio Small bad Large good Speed control Fixed Feedback control Structure cost Simple low cost Slightly complicated control circuit is not so expensive by the use of ICs Magnetic head fixed
215. r 1 1 1 V1 Master Bus Controller V2 Master Bus Controller Voltage Voltage Regulator Regulator EMI Filter 1 12V Breaker amp 9 o a E ims a 3 gt SSSA RSS AIA wN RSS ER RR RSQ meee R amp S NNN AANEEN A NNN gt SSSSSSSS RSA SSSS NGN SSS Rss Rss 0 SSSSSSSN SS SSSSNSCS SS SS ANN T TANN A ANNANN T NS ANET EN A T EN Appendix 7 2 8 EFBD 7 Vision Processor Appendix 7 2 9 EFBD 8 CPU SSS SSSSSSSSS Ejection Module SSS a ANNT NNN GSR 7x a Sis SSS lt a SS 55348 SASSER aea sna 555 NNA 555505 55 5555 SSAA 5 5 0 5 5 5 os nos os E c E c ev To m as as a a a 88 2 coo E Er 4 Sd ee 00 Pe
216. ra with the new WFC3 camera and replace the RSU s in the process We look at the DR from a systems point of view in this section The basic functional and performance requirements were provided in the RFP 1 and these were broken down to give detailed functional and performance requirements The DR has the following major systems 1 Vision The vision system is comprised of the LCS 3D laser scanner four mini cameras and 4 TEE P i IR sensors enabling the operators and the DR to be aware of the environment Figure 4 1 DR Overview 2 Two manipulator arms Each arm has a span of 2 4 m with six degrees of freedom and a tip resolution of 0 025mm translation and 0 011 degrees rotation giving the DR the ability reach and access all parts of the workspace 3 Communication The communication system enables the DR to constantly update ground control about the workspace situation and receive new commands and scripts 4 Survival The survival system enables the DR to keep alive and maintain its system This includes the thermal control and the fault monitoring and control system 5 Control The control system controls the process and actions carried out by the DR to complete the mission 6 Tools The tools enable the DR to interface with the HST in order to perform its mission These seven systems enable the DR to satisfy all given customer requirements In the following sections we present the customer
217. ration of Operational Concept Documents American Institute of Aeronautics and Astronautics H E R O and Frontier Robotics Interface Control Document Wertz and Larson Space Mission Analysis and Design Third Edition 1999 Microcosm Press El Segundo California AFD1000 Series Active Force Tools http www midwestthermal com afd1000 htm Davies BL Harris SJ Lin WJ Hibberd RD Middleton R Cobb JC Active compliance in robotic surgery the use of force control as a dynamic constraint http www ncbi nlm nih gov entrez query fcgi cmd Retrieve amp db PubMed amp li st_uids 9330539 amp dopt Abstract Samson C English C et al Imaging and Tracking Elements of the International Space Station using a 3D Auto Synchronized Scanner National Research Council Institute for Information Technology April 2002 Berinstain A et al Laser Ranging Imager for Planetary Exploration MDR Optech http www neptec com products space vision les specsheet html NepTec online LCS specification Matching 3D Models with Shape Distributions by Robert Osada Thomas Funkhouser Bernard Chazelle and David Dobkin Princeton University Sierra Surplus Trekker Tarp http www sierrasurplus com trekkertarp html 72 11 Bibliography 1 2 3 4 5 6 7 8 9 10 11 12 13 14 ANSI AIAA G 043 1992 Guide for the Preparation of Operational Concept Documents American Institute of Aeronautics an
218. rd size 11 was used for the mass number 5 8 5 5 Tool Mass We estimated our tool mass based on their volume calculated from the solid models and the density of the selected material titanium to gain a first order approximation of the tool mass Given the preliminary nature of our design this was deemed to be sufficient 8 5 6 Motor Electronics This was estimated by searching for a terrestrial version of the electronics required to control the motors and searching for their mass Masses of circuit boards of seemingly similar capability varied largely any where from 25g to 200g therefore a middle estimate of 100g was chosen The overall contribution of the electronic components is small and therefore a rough estimate such as this one can be made given a large margin of 20 8 5 7 Thermal Protection System We found it extremely difficult to locate masses for commonly used solar blanket materials such as aluminized mylar or beta cloth Therefore we selected a more terrestrial material a heavy camping tarp which was highly likely to have a larger mass per m 2 than the solar blanket 68 materials We applied five layers of our thermal blanket to the outer surface of the DR body and arms to protect its internal components Mass was calculated accordingly using the figures for the terrestrial tarp material 13 8 5 8 A Final Note Any components of our system located in the GA or EM were not included in our mass budget These items
219. re ep re EROR 49 7 2 2 CablngLayOut 5 RO eio br e et pr RE IPOs CL rt 49 42 3 Functional Block Diagrams eet iter REP e Vere ee 50 1 3 ELECTRICAL SYSTEM IMPLEMENTATION e red er edere 52 PIA Power BUSES ioina EE 52 3 27 BAN APR EE 53 7 3 3 Electrical Mass Budget aet er esu atre pe Pe ere epe to SE 53 7 4 AULT TOLERANCE an eo DE I EIE 53 7 4 1 Automatic Breakers and Fault Recovery esee eene teeth eren eren enne 53 742 PowerBus Redundancy e 54 743 Data Bus 30 54 7 5 POWER DEMAND cette ritur qu itr D ERIT RR HR EN ENS 54 7 6 DESIGN TRADEORES Her e E Ire reo desi he 56 7 6 1 Complex Multiple Redundancy vs Redundancy through Duplication esses 56 7 6 2 Centralized Device control vs Distributed Device Control sse 56 MECHANICAL SUBSYSTEMS se tha epo etae etae pose Po seen Peto 57 8 1 MECHANICAL REQUIREMENTS roit a n eee i Here eee ee rer 57 8 2 PHY SICAL ARGHITECTURE sarra A O n nere nent nien ere Reti inen 57 6 2 1 Overview of Mechanical De
220. re on along guide rails 4 2 3 8 5 Monitor force moment on all axes to ensure that jamming does not occur 4 2 3 9 Replace Latch A 4 2 3 9 1 Locate released Latch A 4 2 3 9 2 Grapple it and bring it into position 4 2 3 9 3 Secure it into position 7 16 interface 4 2 3 10 Replace Ground Strap 4 2 3 10 1 Release ground strap from temporary clamp 4 2 3 10 2 Bring GS back to position on WFC3 4 2 3 10 3 Secure GS in position on WFC3 4 2 3 11 Replace Blind Mate if automatic function fails 4 2 4 The DR shall be able to perform the following functions to make the power and data connections for the gyros 4 2 4 1 Release blind mate connector same as 4 2 3 3 4 2 4 2 Connect conduit harness to WFC3 4 2 4 2 1 The DR End Effector shall have the ability to grapple the conduit harness that may in the worst case be loose cabling floating in space 4 2 4 2 2 The DR shall be capable of tracking the conduit harness and returning this information to the DC amp H system 4 2 4 2 3 The DR shall have the ability to mate conduit harness to the WFC3 through the use of the circular connector interface on the WFC3 This will require positioning the circular connector correctly on the WFC3 prior to mating this may include a specialized tool or use of the DR End Effector 85 4 2 4 2 4 The DR shall have the ability to disengage itself from the conduit harness without undue harm to the harness 4 2 4 3 Open Bay and make 1553 data bus connection through
221. reaker 12V Breaker Controller Pu Bus D1B 1553 iu m BUS P3A BUS P3B ax Appendix 7 2 11 EFBD 10 Mini Camera Video Unit Video Camera Voltage regulator Bus Controller Bus V1 NTSC BUS 12V E E E ii 2 gt 135 Appendix 7 3 Power Demand Power Required W 68 MGS sts Gripper Wrist Yaw Motor 17 Arm Wrist Roll Motor 17 136 Appendix 7 4 DR Cable Mass Appendix 7 4 1 Power Cables Wires current 2 of wires Insulation q diameter thickness diameter at current current mm there return total interface 0813 050 025 0813 050 _ 024 2 2 4 7101 1024 050 0 46 0 254 050 __ 0 09 Body Bundle 338 0643 0500 009 1 8 136 0320 0 500 007 us P7 us P8 0813 0500 023 0 643 0500 077 0813 0500 _ 0 32 0 500 0 09 137 Appendix 7 4 2 Power Sample Calculations Derating Considerations N number of wires in bundle I req current required I wire individual wire current I bundle current in wires after derating If N gt 15 I bundle I
222. redundant 12V busses on each arm and a primary and redundant 12V pair for the body These 10 5 primary 5 redundant busses will supply power to the electronics heaters sensors and the tool caddy 7 2 2 2 Data Cables Data will be supplied to and retrieved from the motors sensors heaters and the LCS via MIL STD 1553 busses There will be a set of primary and backup busses for each arm and the body Couplers and stub connections will be used to connect components to the buses Video data from each of the four mini cameras two at each end effector will be transmitted along dedicated primary and redundant video busses The complete cable layout has been included in Appendix 7 1 The map illustrates both arms below each other because of space limitations for presenting the map The actual design will have the body and head in the middle of the robot and the arms come out of either side The boxes that are diagonally hatched in the cabling layout diagrams represent the external interfaces for the DR These systems have links with the DR but are not physically part of the DR The cable layout diagram has been broken down into 6 subsections listed in Table 7 1 below for clarity A map of the DR has been provided to show the integration of these subsections Layout Map 744 Table 7 1 Cable Layout Breakdown 7 2 3 Functional Block Diagrams The complete electrical functional block diagram of the DR is seen in Appendix 7 2 A
223. rizontal Resolution 500 TV Lines Pixel Size IK 52V 9 9 um H x 9 9 um V IK 53V 7 4 um H x 7 4 um V Scan Frequency Horizontal 31 469 kHz Vertical 59 94 Hz Synchronizing System Internal External HD VD HD VD inut output area selected by rear panel switch Sync Modes All pixels scanning Partial scanning 1 pulse trigger sync reset Pulse width trigger sync reset 1 pulse trigger sync nonreset Pulse width trigger sync nonreset Reset restart Standard Subject Illumination 400 lux F5 6 Gain off Minimum Subject Illumination 1 lux F1 4 manual gain set to maximum S N Ratio 60dB Video Output 1 0V p p Output Impedance 75 Ohm unbalanced IR Filter None Lens Mount C Mount Gain Switch Off OdB On 0 to 18dB Electronic Shutter Settings Off 1 60 1 100 1 250 1 500 1 1000 1 2000 1 4000 1 10000 1 50000 1 100000 Rear Panel Settings Mode Sensitivity Sync in out Weight 45g 1 59 oz Dimensions 29mm W x 29mm H x 29mm D Connector Hirose Part Number HR10A 10R 12PB Environmental Spectra Sensitivity Characteristics IK 53V 1 3 Inch CCD Camera Operating Temperature 0 to 40 Centigrade Storage Temperature 20 to 60 Centigrade Humidity less than 90 relative Vibration 70m S 10 to 200 Hz Shock 700m S 1 14 VEL Spectra Sensitivity Characterist
224. rotation motor GNM 5440 M max M max max reversible Kg Ibs mm in Nm oz in Nm oz in 5 6 1 1 0 2 20 251 9 88 2 7 382 3 13 1 841 85 9 33 1 1 0 2 20 251 9 88 2 8 396 5 13 1 841 85 14 5 1 1 0 2 20 251 9 88 3 8 538 1 13 1 841 82 17 1 1 0 2 20 251 9 88 4 2 549 8 13 1 841 78 30 1 1 0 2 20 251 9 88 8 1 133 13 1 841 72 35 1 1 0 2 20 251 9 88 8 1 133 13 1 841 69 For notes on technical data refer to Technical Information Specifications subject to change without notice MME0402 MicroMo Electronics Inc 14881 Evergreen Avenue Clearwater FL 33762 3008 Toll Free 800 807 9166 Fax 727 573 5918 info micromo com gt www micromo com ENGEL Series G2 6 amp G3 1 Dimensional outlines for 3150 G2 6 300 11 811 179 2 402 Dimensional outlines for 5440 G3 1 7 047 GNM 3150 G2 6 2x Front View me 10 O99 394 KEY DIN 6888 3 3 7 9 66 000 4X M5 6 236 DEEP 23 906 38 1 496 39 1 535 826 3g 115 1 142 m 1 969 E 591 L 251 3 071 9 882 GNM 5440 G3 1 4x M6 7 276 DEEP 2x11 433 Front View 2x 25 5 1 004 MicroMo Electronics Inc 14881 Evergreen Avenue Clearwater FL 33762 3008 Toll Free 800 807 9166 Fax 727 573 5918 info micromo com gt www micromo com
225. rs are located on the grapple fixture to route the power to the DR Each connector will carry a full set of cables allowing the DR to fully function in the event of a connector fault 7 3 1 2 Design The electrical devices on DR have been divided between the buses in such a way so that the noise and back EMF associated with motors and other actuators cannot affect sensitive electronic components Therefore motors and electronics will not be drawing their power from the same bus Additionally the DR heating units can draw large amounts of power and for reasons of limiting the wire gauge required are connected to their own independent power bus Exceptions to this paradigm are the heaters in the body of the DR which have been included on the same bus as the LCS system for reasons of limiting the buses required and matching Since all the motors could not be placed on the same bus for reasons of limiting the wire gauge it was also decided to stagger the connections such that if a bus failed and its backup also failed a critical joint such as the shoulder would not be rendered completely inoperative In this worst case scenario at least one DOF in the shoulder would still be active and provide the ground control with some options as to removing the arm from Hubble Although one might think that this is an example of scope creep we feel that this added error tolerance is essentially free as the motor power needs to be divided
226. rturbations in 2 its position Next ground controllers would command the DR to drive its wrist motor to turn the bolt the desired number of times Ground control would upload a part of the above instruction set to the Main CPU on the DR which would then execute the instructions by coordinating subsystems on board the DR In this manner by stitching together the various commands that are used to trigger mission tasks on board the DR ground controllers will ensure that the mission objectives will be met In the event of CPU failure ground controllers have the capability to command joint motors and other subsystems directly in manual control mode This mode provides extra reliability but does not offer the same level of performance since the real time autonomous functions performed by the CPU are unavailable 5 6 2 External Interfaces Ground control needs to interact with NASA mission controllers and operators while performing servicing tasks on the HST In the likely event that operations need to be modified or updated due to unforeseen complications during the mission DR GC will collaborate with HST specialists and operators to lay out the functional flow and objectives of any necessary operations Ground control also needs to interact with GA Ground control to coordinate the operations of the two robotic elements of the RSS The following information will regularly be exchanged between DR and GA ground controllers during the operational
227. rvicing the DR will have to ensure that all loose parts are stowed properly and not set adrift in open space At the completion of servicing task all tools and components removed from the HST will be properly stowed on the EM After servicing is complete the GA will stow the DR back onto the EM placing it within its stow fixtures and releasing the grapple fixture once the DR has powered down Once GA has stowed itself the EM will jettison from the HST DM and will be de orbited The De Orbit module will remain attached to the Hubble for future controlled de orbit of the HST DM complex 5 2 1 Operations Timeline This section describes the basic timeline of DR operations We decomposed the Functional Flow Block Diagrams from the mission objectives and detailed them sufficiently to allow the identification of all significant functional requirements imposed on the DR by its mission Listed below are the top levels of functional flow during the major parts of the DR mission A more detailed functional flow of the DR system is presented in the detailed Functional Flow in Appendix 1 1 Launch 1 1 Pre launch system check 1 2 DR enter keep alive mode 5 Servicing 5 1 Deploy DR 5 1 1 Activate GA 5 1 2 Move to DR stow site 5 1 4 Grapple DR 5 1 5 DR Wake up amp Checkout 5 1 6 DR standby 15 5 1 6 1 DR switches from Normal to Sleep Mode 5 1 6 2 Await command signal from ground control 5 2 Power Augmentation 5 2 1 Conduit Deploy
228. s For an external control system no We are working with several groups to do this for autonomous vehicle operations rovers mining vehicles etc as 112 well as robotic arms for manufacturing environments But these are preliminary efforts right now Internally we use data from scan patterns to plan the next scan pattern within the scanner In other words the object pose estimation from one scan pattern will change the size shape and position of the next scan pattern This approach could generally be applied to a pan tilt unit or even a robotic arm though the computations would be different and more complicated 2 DOFs for scanning mirrors or pan tilt is easier than multi DOF for robotic arms gt 6 Lets say had two LCS s operating at the same time side by side gt would they interfere with each other we re required to have single gt fault tolerance in our system etc we wouldn t necessarily run them at gt the same time but who knows Generally no We ve never had a reason to have two running at the same time or interfacing with each other That being said our current control software can control more than one scanner at a time and use the data however you want e g have the data from one scanner affect the commanded scan pattern for the other scanner We haven t done this but there s no reason you couldn t gt 7 How do scientists in the machine vision field estimate the gt computational cost of 3d
229. s Convection Cooled 512 KByte on chip with ECC CPU Core Clock Rate MEMORY VOLATILE 256 MByte SDRAM Reed Solomon Protected Double Device Correction NON VOLATILE 8MByte EEPROM ECC Protected 7 0 MByte EEPROM available to user 0 5 MByte Primary SuROM 0 5 MByte Secondary SuROM Autoswap on Primary Failure Board Support Package Detailed Specification e User Manual Interface Control Documents Software User s Manual SUM e Certificate of Conformance cPCI BUS Startup ROM Source Code 6U e Functional Test Procedure i Test Plan 32 bit 33MHz Master Target amp Syscon Peripheral Test Log 1553 e Functional Test Report BC RT MT e Environmental Test Procedure Flight Only SEU Immune Test Plan SERIAL Test Log UART Asynchronous LVDS 2 USRTs Synchronous LVDS PROGRAMMABLE 1 0 32 Programmable General Purpose 1 0 GPIO e Environmental Test Report Flight Only 7 25 watts typical dependent on clock rate MIPS requirements 5Vfor 1553 interface 3 3V for rest of board MAXWELL OPERATING SYSTEM GUARANTEE VxWorks Tornado TEMPERATURE 40 C to 70 C Rail For the most current information on Maxwell products visit www maxwell com Worldwide Headquarters Maxwell Technologies Inc All specifications are subject to change 9244 Balboa Avenue San Diego 92123 USA PHONE 1 858 503 33
230. s and resolve the situation Ground control will be able to override the emergency stop signal if for some reason the system is triggers a halt and operators determine that it is safe for the DR to continue 5 8 Operations Tradeoffs Minimum vs Maximum Autonomy Greater autonomy could be used to enhance the overall performance of the DR but we believe that the cost in terms of mission risk and complexity would be too high An autonomous system has more failure modes and thus would be more dangerous in close proximity to the HST For this reason we have designed the DR to use the minimum necessary 26 Active Force Control vs Purely Scripted Motion Operators using only scripted motion are likely to have great difficulty in performing the WFC due to the small tolerances on each rail 0 1 They would have to do stop go control finely tuning the commands to unstick the rails Active force control while complex is current technology and is well suited to this application We felt that the extra demands on the DR software were justified by the increased mission safety resulting from speeding up the WFC installation so that it is not in danger of freezing while it is stuck and partly inserted 27 6 Control System This section discusses the DR control system The major requirements that drove various design decisions are itemized and are listed from general to specific and hence more quantitative The control system architec
231. s low cost evaluation and prototyping of Thermofoil heaters Available from stock it contains 14 heating elements you can arrange in more than 1000 combinations When ordering the complete kit one sheet 6 x 12 of acrylic PSA is included for easy installation Specify acrylic PSA for individual heaters if desired Specifications Temperature range 200 to 200 C 328 392 32 to 100 C 26 212 F with acrylic PSA Material Kapton FEP 0 0020 001 0 05 0 03 mm Resistance tolerance 15 Minimum bend radius 00307 0 8 mm 06x22 10x22 25 x 56 115 56 _ 38x56 _ 146 55 160 166 56 9 19 x 48 15 x 48 66 Da 1 66 76 3 46 x 76 38 x 76 1 25 76 1 15 76 60 http sourses http www servosystems com harowe_resolvers htm http www polysci com docs DigitalResolverDS pdf http www globalspec com specifications spechelpall name motion_controllers amp comp 44 used resolver reference http www dynapar encoders com harowe sections product sizell specsl htm resolver mass reference http www amci com resolvers resolvers r1 1 asp Thermocouple Probes For information about thermocouples see page 487 Air Immersion Thermocouple Probes with Flat Pin Mini Connector du gt 2 Flat Pin 096 Wd P A Mini 125 connector 4 amp 5 Probes have male flat pin mini connectors Note Respo
232. s on a number of factors The length of time to take a single point measurement depends on the integration time of the detector which we control If the object is close we only have to integrate the reflected light for a very short time e g 20 microseconds If it s far away it might take hundreds up to thousand of microseconds per point Light intensity falls with the square of distance so the integration time correspondingly increases with the square of object distance 111 That covers the time for a single point measurement How long the entire scan takes depends on how many points are in the defined scan We typically use up to 1024 points in a non raster scanning pattern such as Lissajous patterns At that rate we can repeat the pattern generally about 2 10 times per second depending on the integration time range to object It scales linearly for fewer points e g with 256 points per scan pattern we could get 4 times as many 8 40 scans per second For raster scans it just scales up linearly If we do 1024 x 1024 and we do 2 10 lines per second as above for 1024 points then it takes about 100 1 5 min 500 seconds 8 min for the total scan We rarely take more than about 3 minutes for a 1024x1024 Lower resolutions scale with the square e g a 256x256 takes 1 16th the time since there is 1 16th the number of points The resolutions available for raster scans are 2x2 up to 1024x1024 and don t have to be square e
233. s will receive the PWM signal through a MOSFET gate node which allows the current through the drain to source to be controlled directly through PWM The motor is in series with the drain and hence we can control the torque of the motor directly Relays can be used for directional control Figure 6 1 shows the motor control circuit 31 24V Vor DCMotor PWM L lt MOSFET figure 6 1 motor control circuit 6 2 3 4 Thermal control Temperature control is necessary to protect the electronic components Active heating is needed to prevent the temperature from falling below 15 C The temperature control system is fully autonomous The CPU on the DR will receive inputs from the thermocouples and switch on the power to the heaters as and when necessary The thermal control system measures and compares the temperatures to decide whether to power the heaters The autonomous nature of the thermal control system ensures that any failures will be immediately dealt with decreasing the chance of damage occurring to the DR See Appendix 6 for a model of the thermal control block diagram 6 2 3 5 DR Main CPU The DR CPU is responsible for sending and receiving commands and signals to ground control as well as all of the other DR actors with the exception of the LSC video cameras and telemetry controller It performs high level tasks which coordinate mos
234. scoseesseceosessecoosssseeceees sadeoeess0soesevseveones POSEE EE sovooeesseaesbesseceseas ies 174 4 1 COORDINATE SYSTEMS ccssssssecessccecssssecsssnsecsessecesesssecsesueseceesaeessessecsesussecseaeesecessecsesaeseseesaeeessenseeses 174 4 2 COMMUNICATIONS AE EEA ERE 174 4 2 1 Emergency Stop 174 4 2 2 From Ground Control to DR GA eese eher ennt tenens eset enne tene essei 174 4 2 3 From DR GA To Ground Control ette ness sere ase nn 174 424 Ground Control to GA Ground Control eese 175 4 2 5 GA Ground Control to DR Ground 8 nsns nsns ese s esee 175 REFERENCES e 176 6 177 61 1 0410 177 6 1 1 FONE ViGW 177 6 1 2 Dn 178 6 1 5 Interface Teeth Detail ie spa PE EO ENE 179 6 2 DR STOW CONFIGURATION ERE A EEE HERE REL TERUEL 180 6 3 CAPTURE ENVELOPE
235. sign eese esee ennt tenete en nentes 57 822 DR GA Int rldces iii notte EP E Seas sabe doau gens IRE RUE PRESE 58 8 2 3 Interface eea et ERU EYE EE E Rhen ree It ebat e 58 8 3 MECHANICAL SYSTEM IMPLEMENTATION rr ettet rtr tete perite 59 6 3 1 JEU mE c 59 832 MANIPULAIOL oe edet eee Sie ate re ces Seok un eene eure te eine e dep tn esed 61 MED EE 62 8 3 4 EE 62 UToobCadady Lite a ette etd ett eh d e ost eae 66 8 3 6 INIA 10 detener a BEE URGE POI re de CRAPO 67 8 4 FAULT LOLERANGE nere erred d epe ite redet e ee etate 67 8 5 MASS B DGETU eese tice reet Cep tede eue IHE Ero 68 851 Cabling and Connector Mass isi iaceo tete eiit pite ERE ep i Fe EHE eset 68 8 52 Boom SStructure Fairings aas t eite erii iiti tree ie eee P reso 68 8 53 Joint Structure ies sia 68 8 5 4 Resolver eene E A nnn 68 8 5 5 TOOL MIS tatoo ote EE RA A A Aeneas LE E 68 6 5 6 Mo
236. signal for first communications y o repeat until acknowledged from DR P e greed em Carry out Handshake and DR Main CPU Tecleved establish Data Link computer 99 DR Ground Control Command GA to move DR out of Bay GA Ground Control Command acknowledge Mission Task Command Flow Levels of Autonomy DR deploy wwe GA Signal initial deploy complete 1 DR Initiate DR deploy operations Actors Command Events Command GA to move DR out of stowage bay GA GC Send command signal comes repeat until acknowledged grapple to DR GC Recieve cm grapple Initiate Full DR power up Initiate DR deployed DR GC Command full DR power up Command DR deploy DR Main CPU Bring all systems online Move arms into deploy configuration computer was successful Execute GA move gt Communicate if GA move DR Motor Controller Communicate if GA move was successful DR Do nothing stay in keep alive while GA moves DR out of stow position 100 ssecons j mos 1 0 5 jeuuou Bue jeuuou uyum Ed beni m suonpuoo jeune uleureyw
237. signed the DR to prevent orbital debris production so as not to create a hazardous debris cloud around the HST 5 1 2 Operational Constraints The DR operates on power supplied from the EM s on board Electrical Power System EPS The DR shall interface with communications systems found on the EM for data communication with Ground Control It is assumed that the EM communication system will be sufficiently reliable and have sufficient bandwidth to allow operation of the DR during all mission phases The configuration of the HST is fixed and therefore all operations are designed to be performed successfully within the envelopes defined by the HST work sites Due to the performance demands of the mission and the lag in radio communications to LEO the DR is capable of performing simple scripted tasks such as tip motions or tool actuation in an autonomous fashion These scripted tasks will always be initiated by ground control The mission must be completed prior to the expected failure date of one of the remaining three RSUs so as to prevent the HST from entering an uncontrolled and unrecoverable spin This puts the servicing phase of the mission no later than mid 2009 5 1 3 Operational Environment When launching the HRV thrusts from the rockets will pulsate and cause the rocket and HRV to vibrate The HRV must withstand these vibrations and reach HST unharmed HST is a Low Earth Orbiting LEO satellite its orbit is in the thermosphere
238. sion objectives The operators of the DR will be specially trained NASA mission personnel responsible for directing the DR in the servicing operations Indirect stakeholders in the DR are the members of the scientific community who will benefit from the extended life and enhanced scientific capabilities of the HST Also the space robotics industry stands to benefit from the technologies developed for this mission and from the experience gained in performing orbital robotic servicing 3 4 Mission Profile 3 4 4 Mission Phases The role of the DR in context of the Hubble Rescue Mission s phases is described in Table 3 1 The scope of DR primary operations is within the servicing phase of the mission The DR acts as a payload on board the EM during the remainder of the mission Launch Pursuit 2 12 days Proximity 1 2 days Off Payload Operations Servicing 30 days Activation Augment EPS Service Ops Install RSUs Install WFC3 Disposal Payload Science Operations Syears None 0 00 De orbit 4days Noe 02 Table 3 1 Mission Phases and Systems 3 4 2 Mission Systems The major systems involved in the execution of the Hubble Rescue mission other than the Dexterous Robot are as follows 3 4 2 1 Hubble Rescue Vehicle HRV This spacecraft is made of two components the De Orbit module DM and Ejection Module EM The HRV will transfer from its initial low earth orbit to perform a rendezvous with the
239. t Touch intemal electronics or instrumentation this could damage transducer and will voi 4 TO AVOID 1031 Goodworth Drive Apex NC 27539 USA Tel 1 919 772 0115 gt Email info ati ia com Fax 1 919 772 8259 www ati ia com ISO 9001 Registered Company T I INDUSTRIAL AUTOMATION will void warmi DO NOT EXCEED INTERFACE DEPTH 5 Transducer must be mounted to surfaces rigid enough to support loads without deflection for best accuracy DRAWING NUMBER 9230 05 1129 03 X axis amp Y axis force Kx Ky Fxy 5700 Ib 25000 Fz 14000 Ib 61000 N Txy 22000 in Ib 2500 N m Tz 24000 in Ib 2700 N m 420 103 Ib in 74x106 N m Z axis force Kz 710x103 Ib in 120x106 N m X axis amp Y axis torque Ktx Kty 3 0 106 in Ib rad 340x103 N m rad Z axis torque Ktz 4 8x106 in Ib rad 540x10 N m rad Fx Fy Tz 680 Hz Fz Tx Ty 820 Hz Weight 11 0 Ib 5000 g Diameter t 6 10 in 155 mm Height t 2 41 in 61 1 mm t Specifications include standard interface plates ATI INDUSTRIAL AUTOMATION _ 23 Chapter 12 Brushless DC Motors Topics to cover 1 Structures and Drive Circuits 3 Performance 2 Equivalent Circuit 4 Applications Introduction Conventional dc motors are highly efficient and their characteristics make them suitable for use as servomotors However their only drawback is that they need a commutator and brushes which
240. t down Communications 6 1 10 5 Shut down processors 6 1 10 6 GC shuts off power connection from EM 6 1 11 GA releases DR 6 1 12 GA standby 6 2 GA shutdown 6 3 EM Jettisons and Carries out De Orbit maneuver 6 4 Mission Accomplished Break out the champagne Appendix 1 2 Contingency Scenarios Appendix 1 2 1 Mechanical failure of the 7 16 tool This following is a detailed description of the operations that will take place if a failure occurs while using the 7 16 tool This process can be generalized to outline the scenario for any mechanical tool failure Further more eliminating steps 2 8 and 2 9 will provide a basic framework for any mechanical failure of the RSS Chronological sequence is in the downwards direction as indicated by the numbering of the blocks 80 2 Mechanical Failure of 7 16 Tool 2 2 Tool Fails 2 6 Ground Support assesses information and determines tool is not repairable 2 7 Ground support transmits new instructions 2 8 Return Tool to Caddy 2 9 Acquire Backup Tool Operations Appendix 1 2 2 Failure of the main power system In the event of a power failure the following operations will be performed o 1 Failure of Main 1 1 Normal Operations Power System 1 2 Power System Fails 1 3 Automatically switch to power backup 1 4 Boot up in safe mode 1 5 Perform EPS Diagnostic Tests 1 6 Transmit Data to Ground Support 1 7 Standby and wait for Commands
241. t of Inertia 58 51445 Payload Kinetic Energy 0 453592 J Payload Rotational Energy 0 08021 J Stopping Distance 0 008 m Stopping Angle 0 007 rad Tip Force F KE distance StaticMargin KineticMargin 111 1746 N Tip Torque T RE angle StaticMargin KineticMargin 23 56776 Nm This load case is less than the 50Nm requirement th Shoulder Torque Normal Tip Load Required Torque T Length TipForce Required Torque 245 Nm Required Power 13 W Elbow Torque Normal Tip Load Required Torque T Length 2 TipForce Required Torque 122 Nm Required Power 6W Wrist Torque Normal Tip Load Required Torque T WristLength TipForce Required Torque 55 5873 Nm Required Power EE Torque 20 ft lb 27 11636 Nm Required Joint Torque T EETorque StaticMargin DynamicMargin Required Joint Torque 54 Nm Required Power 3 tip acceleration 0 05 m s 2 EE Payload 200 Ib 90 71848 Tip Force F ma 4 535924 N 149 Appendix 8 3 5 General Manipulator Joints Calculations MANIPULATOR ARM JOINTS Dominant Load Cases Joint Torque Shoulder Mass Budget mass 4 0 03 Torque Estimated Motor Mass Qty Total Shoulder 11 3 kg 4 45 4 kg 7 7 kg 2 15 3 kg 5 7 kg 6 34 0 kg Total Mass of Joints 94 7 kg Estimated Boom Mass Qty Shoulder 3 3 kg Upper Boom 15 0 kg Lower Boom 7 7 kg Wrist 0 4 kg Total Mass of Arm Structure 150 Appendix 8 3 6 General Manipulator Material Selection Calculations Material Properties BendingStress 1 75 Density 114285714 3 Pa
242. t of the autonomous systems on the DR The CPU will give commands to the following systems Vision System Processor e Update the workspace definition these tasks are actually carried out by separate visions system controller Motor Controllers Start stop e Required angles 32 e Required speeds e Perform test e Enter stow configuration Communication e Establish Data Link with Ground Sensors e Power up e Perform test GA e Emergency Stop Self e Switch into desired mode 6 3 Vision System Architecture The DR vision system includes a suite of sensors which it uses to perceive its workspace The sensor data is interpreted by a dedicated vision system processor which through machine vision algorithms locates the DR relative to the HST and provides essential feedback for the control system The primary vision sensor will provide the data for workspace registration and a secondary system will provide additional camera angles and close up views of specific objects We have selected a pair of NepTec LCSs to act as our primary vision sensor with one in reserve as a back up to provide single fault tolerance Two Toshiba mini cameras will be mounted on the end of each end effector and will provide additional camera angles and limited stereoscopic ability our system however does not require this capability 6 3 1 Selection of a Primary Vision System Sensor There are a number of requirements on the DR design which will dire
243. ter PortC PortC Interrupt request register IRQpC PortC interrupt mask register MportC Option2 register Option2 PortD Input Output register PortD Ports control register CPIOB PortE Input Output status register PortE PortE Input Output control register ClOPortE Buzzer control register BEEP Buzzer output pad allocation PBO amp PEO function used with BUen and BuzzerPEO control bits Timer Clock Selection Timer control register TimCtr LOW Timer Load Status register LTimLS 4 low bits 22 HIGH Timer Load Status register HTimLS 4 high bits 22 counter input selection register PA3cnt counter input selection Main Interrupt request register IntRq Read Only Register CIRQD SVLD Level selection SVLD control register SVLD SWB clock selection SWB clock selection register CIKSWB PortD status SWB buffer register SWbuff SWB Low size register LowSWB SWB High size register HighSWB input output Ports PortB Hi Current Drive capability EM6607 06 04 Rev Copyright 2004 EM Microelectronic Marin SA www emmicroelectronic com 1 Pin Description for EM6607 EM6607 Pin Nb Pin Nb Pin Name Function Remarks 24 pin 28 pin 1 1 port A 0 input 0 port A interrupt request tvar 1 2 2 port A 1 input 1 port A interrupt request tvar 2 3 3 port A 2 input
244. that s up to the task well that about sums it up really appreciate your help thanks Kristian 109 Dr English s Response Kristian See my answers after each question below Regards Chad This has been proven several times We flew the LCS on shuttle flight STS 105 August 2001 and performed scans during day and night in orbital terms passes We showed that the scans were identical This was published Also in July 2003 we did tests with NASA at Johnson Space Center where the shone a mini sun lamp simulates wavelengths and intensities of sunlight in space during scans and found that there was no effect on the scan results The solar immunity comes from a few sources First the laser wavelength in LCS is 1500 nm which is a low point in the solar spectrum The detector we use is only sensitive from about 900 nm to 1700 nm so any other solar light won t show up Then we also put a narrow bandpass filter in front of the detector that only lets in 1500 nm 10 nm Next although LCS has a total field of view FOV of 30 deg by 30 deg the instantaneous FOV is only about 3 5 degrees meaning the detector can only see 3 5 degrees at a time and we move this small FOV around the big FOV as we scan This small instantaneous FOV means that the detector can only pick up a small amount of solar light during each measurement compared to wider FOV sensors like normal cameras Combining these there is very little intensity
245. the DR is handled by infrared proximity sensors placed in strategic locations most likely collision points TBR Data from the sensors will be assessed by the proximity controller on the DR This controller has the highest priority along the 1553 bus to the control computer The 1553 bus controller will be designed to stop all tasks and allow passage for the stop signal This priority will be maintained through the DR GA interface to ensure immediate stopping 4 2 2 From Ground Control to DR GA Ground control will be responsible for sending the following signals to the DR or GA e Start next operation e Stop all operations basically a halt command that acts like an emergency stop e Upload new scripts e Upload software patches e Tool selection signal 4 2 3 From DR GA To Ground Control The DR will send the following information to ground control e Self check results 174 Operation successfully completed containing operation description Error report containing the process and system component where the error occurred Up to date coordinates as calculated by LCS DR or Kinematics Modeler GA Video Feeds Force torque sensor data 4 2 4 DR Ground Control to GA Ground Control The DR ground controllers communicate the following information to GA ground controllers e Position Data when move required This will be sent as coordinates to which the origin needs to be shifted relative to the current position of the origin See Coordin
246. the armature current Vy is the back emf voltage due to the shaft rotation 0 For the mechanical equation we lump the motor inertia with the load inertia into the term I The radial position of the shaft 0 is related by 10 0 Ki T where C is a damping constant in the model and T is some externally applied load After some algebraic manipulation we get K KV 2_ 0 R R a a 104 C T A simpler way to write it would be K V I where the new constant 15 K R C R And define Ko to be K E then K K a 103 The final model relates the radial position derivatives in terms of the input voltage Va K V The Laplace transform of the equation is sO s x zs 1 K V s KT s 11 2 Plant and Controller Block Diagram Externally applied Torque 0 actual Transfer Fen Integrator controller Q sensed Sensor V rad Sensor noise Fogle Position signal from Processor v Fen Q represents 0 and t represents Qdes ired is compared to Q sensed and the error is sent to the PID controller that outputs the required armature voltage to the motor We selected a P controller because it satisfies all our transient and steady state need Using the data from the motor specification sheet we get Ra 9Q K 0 043 Nm amp We require the rise time to be 2 5 seconds Hence if w
247. the torque needed to unscrew the connector Again the tool uses the common interface Figure 8 8 Right Angle Tool 8 3 4 3 5 Multi Purpose Clip Tool The general purpose clip has been redesigned to account for the different clipping envelopes for gripping the ground strap and the conduit The new clip has a circular end that will allow the gripping action to be more flexible and versatile When clipping the conduit to the handrail the circular end is sized such that it closes to rigidly grip them in place As for the ground strap the redesigned clip is allowed to close beyond the horizontal pivot line so that it can enclose smaller clipping envelopes for gripping the ground strap to the handrail One hand of the clip will have the typical tool end effector interface for the end effector to grip This is seen in Figure 8 9 below labeled Tool EE interface The other hand of the clip will have a circular towel bar that will allow our secondary gripper to open the clip when it strokes the two clip hands together The reason to the towel grip design is because the stroke motion will follow a radius of curvature and so the towel bar design can interface with the end effector while allowing the radius of curvature to be followed without inducing stresses on the end effector or the clip 65 Towel bar Figure 8 9 Multi Purpose Clip Tool The springs in the clip will always be in compression and so will always apply a force to close
248. tion 74 5 1 5 DR Wake up amp Checkout 5 1 5 1 DR GC shuts off keep alive system 5 1 5 2 DR GC powers up DR via main connection across GA 5 1 5 2 1 DR Switches from Keep Alive to Normal operating mode 5 1 5 2 2 DR powers up processors 5 1 5 2 2 GC and DR establish communications 5 1 5 2 2 Guidance online 5 1 5 2 3 Power up sensors 5 1 5 2 4 Power up actuators 5 1 5 2 Perform static self test while stowed 5 1 5 2 1 Perform sensor static self test 5 1 5 2 2 Perform arm static self test 5 1 5 2 3 Perform joint static self test 5 1 5 2 4 Perform manipulator static self test 5 1 5 3 Release Stow Fixtures 5 1 5 3 1 DR GC trigger stow fixture release 5 1 5 3 2 Verify latches released sensors and video feed 5 1 5 2 3 GA moves DR clear of stow fixtures 5 1 5 4 Move GA DR to home position 5 1 5 5 Perform DR dynamic self test motion and performance 5 1 5 5 1 Perform joint dynamic self test 5 1 5 5 2 Perform manipulator dynamic self test 5 1 6 DR standby 5 1 6 1 DR switches from Normal to Sleep Mode 5 1 6 1 1 Moves arms to standby configuration at safe distance from HST 5 1 6 1 2 Power down motors 5 1 6 1 3 Power down sensors other than thermal and collision 5 1 6 2 Await command signal from ground control 5 2 Power Augmentation 5 2 1 Conduit Deploy 5 2 1 1 Activate GA 5 2 1 2 Activate DR 5 2 1 2 1 GC commands DR to switch from Sleep Mode to Normal Mode 5 2 1 2 2 Power up sensors 5 2 1 2 3 Power up actuators 5 2 1 2 4 DR Sel
249. to move to angle continuously check output of resolver to determine once operation is finished Signal move completed or raise error code uoiusej jeonuapi u p puewuos usaq seu yesuogisod Inun eyes pue ajSuy wor uodey 5191104005 WwaysAs pue dew mey 105592014 0191545 UOISIA peaj 10 SJOSUBS iod Teawy punoqino SPUBWLUOQUOIOWY lepow jies siep n pue arapay Ha 1001 189 Buiuajsr uoneuuoju SMES mpeg 0j Uais 101 u09 punoid auinboy oL puewwog passag euiuuajag s10 oy 10 001 2992195 jo sione PUBLULUOD 98 Mission Task Command Flow DR Establish Communications Actors Command Events Initiate Communications Monitor Connection of Startup Routine Comm System DR GC Send Communications Continually poll recievers Startup Command
250. tor Electronics ecccccccccccesccscccccecssssscsccsccecsssssssccsesecsssscescesscecsssessseesssscsesesssessssccsesessesseccesesesscesesecsecess 66 857 Thermal Protection System iia seitdem iei Er Enero 68 0 9 cA Ing NOL s ote tee E ista T EE dt res e E OCIO re de M 69 8 6 DESIGN LRADEOEFES deed re eterne e eite reete iet OR Ede d en tete ns 69 8 6 1 69 8 02 BOOMS 69 9 CONELUSIONS c 71 9 1 POSSIBLE IMPROVEMENTS e cto e ee e diee ces E Ce dee esc ric A RRS 71 10 AA ASEENA AEAEE PASEAN 72 11 BIBLIOGRAPHY 73 APPENDIX 1 FUNCTIONAL FLOW aa aaia naa 74 APPENDIX 1 1 FUNCTIONAL FLOW BISH N INE E E E E aes 74 Appendix 1 1 1 Launch Phase Functional 74 Appendix 1 1 2 Pursuit Phase Functional 74 Appendix 1 1 3 Proximity Phase Functional 74 Appendix 1 1 4 Capture Phase Functional Flow 74 Appendix 1 1 5 Approach Phase Functional 74 Appendix 1 1 6 Jettison Phase Functional Flow eese eene
251. tor shaft N of EE 114 Thermocouple Voltage voltage drop proportional to temperature relative to normal temperature degrees Celcius 120 to 120 8 bits Touch Sensors N A 0 and 1 1 bit Limit Switches 28 on off state To indicate whether a motor has reached the end of its range of motion N A 0 and 1 1 bit DR CPU Position Data To position DR into the required Workspace in terms of x y z coordinates 0 to 15 14 bit 0 001 Emmergency Stop N A 0 and 1 1 bit Motor Microcontrollers Heater switches Switch control to turn heaters on and off as necessary N A 0 and 1 1 bit Ground EM Comm Command data and engineering data 11 8 Mini Specification for motor control Level 2 Function Inputs Outputs Psuedocode Loop Mo tor Shaft position monitor 1 1 1 data input pulse count direction Time input from CPU position and velocity When motor are in motion and when requested 115 Read pulses for resolver Read time from central computer Calculate position from pulses Calculate velocity from position and time data Provide these data to requesting module End loop Function Monitor Force and Torque 1 1 2 Inputs data inputfrom sensor Torgue and force data from T F sensors Outp
252. ts them accordingly it will also send out data from the motor controller to other modules and GC Motor Command Calculator This module will take in data from the power request module F T monitor overload monitor motor shaft position monitor and determine an appropriate motion for the arm as a whole or a specific motor These instructions are then sent out to the appropriate device after its power request has been satisfied Motor Gearbox Output Shaft Monitor This module will continuously monitor the output data of each resolver and calculate the current angle angle rate and angle acceleration This data will be communicated externally via the Command Interpretation module Power Request Module The power request module will interact with the power regulation system in requesting power for motors While the power regulation system does not directly control the function of the motors it does control which devices are currently have a full power supply and which are in standby 45 Force Torque sensors F T data at EE earth commands via external comm Script commands 4 Emergency Stop command Force Torque data Force Torque data Force Torque data destination commands emmeregncy ouput data stop Motor Shaft Resolver data to from power regulator rate and angle information iti t position data motors to turn on motors available angle commands r
253. tudes of E V and as if it were a dc circuit But first note that when E and are in phase the motor mechanical power output before friction windage and iron losses i e the electromagnetic output power is mo Ul Q where m is the number of phases and are the amplitudes of phasor 1 and Am and the electromagnetic torque is p Pa menu om o r where 20 is the rotor speed in Rad s and p the number of poles m Nm D Dus UI 4 The actual shaft output torque is Tload Tem Tlosses 5 where Tj ses is the total torque due to friction windage and iron losses Dropping the amplitude modulus signs we have Ioue Amd 6 Or Ayn 7 Performance of Brushless DC Motors Speed Torque T curve Still assuming W L lt lt R and position feed back keeps V and E and hence 2 in phase the voltage equation can be simplified in algebraic form as V E RI 8 Substituting relations of E and T we obtain Page 12 8 2R Vg uc um 9 2 mpi V R Or 2 T 10 m pA 2 The corresponding 7 0 curve is shown in Fig 13 for a constant voltage Efficiency Efficiency is defined as the ratio of output power and input power i e 1 1 TO where and Tigad r In term of the power flow Pin PFe Pmec 12 where mRf is the copper loss due to winding resistance Pre the
254. ture is then outlined through a discussion of our control philosophy and how the requirements contributed to its design The software architecture is then discussed and supported by a number of software architecture diagrams The requirements that the software imposes on the hardware are listed in addition to a number of key computer hardware components that we feel will be necessary to fulfill the software requirements 6 1 Control Requirements 6 1 1 Functional The DR shall control The position of the tool manipulator The position of the general purpose manipulator The camera orientation at each end effector The LCS system orientation 6 1 2 End Effector Position Accuracy The DR shall e Have an accuracy of 1 and 1 relative to the commanded position Have a tool end effector such that can apply a torque of at least 50 ft lbs with an accuracy of 15 6 1 3 End Effector Position Resolution The DR shall e Have end effector tip resolution better than 0 1 and 0 1 6 1 4 Vision System Sensor Requirements The DR shall e Have two cameras on each end effector to provide a single fault tolerant means of obtaining viewpoints of the workspace e Provide the vision system software data to register and track objects to within the aforementioned accuracy in all lighting conditions e Be able to visualize the entire workspace with no regions that cannot be visualized by either moving the end effector cameras or pivoting th
255. tware processes this data and produces output signals to actuators devices that creates the necessary response The major part of the control software is the control of the motors According to the calculated response time and due to the fact that we decided that absolutely no overshoot is acceptable we decided use a second order control transfer function with simple P control with data from the resolvers forming the feed back loop Central C amp DH The central CPU will be located in the avionics box in the EM Since the vision data processing requires large processing powers we decided to have a separate CPU to perform model matching and analyzing the data from the LCS and the four Mini Cameras 4 2 2 System Block Diagram Hubble Space Telescope Grapple Arm Dexterous Robot WE Tener ae Toa carent conor E Tools Sensor fem Thermal Control System Je End 1 Sensors Meer TCS nant Mechanisi Solar Heat Sensory p Structura 1 17 Mechanisms Mec
256. uch as temperature data joint positions and speeds forces torques and other engineering data to ground control o DR CPU shall initiate the communication connection upon which telemetry is transmitted to GC 5 7 2 Autonomous Architecture 5 7 2 1 Subsystem Controllers Manual Mode At its most primitive level the DR will allow ground controllers to directly command each individual joint This basic level of functionality ensures mission success even in the event that the more capable CPU controllers fail 5 7 2 2 Main CPU Motion Control At its normal operating level the DR will be augment user commanded motion with autonomous control that will significantly improve performance during normal operations The main CPU of the DR will be able to compute appropriate motor commands for each of the 6 joints per arm to achieve coordinated motion at the end effectors We determined that this functionality is desired since the several seconds of communications lag between GC and the DR precludes real time control Additionally coordinated control of joints is required to achieve motion along constrained paths as during the insertion of the WFC3 5 7 2 3 Main CPU Active Force Control In addition to computing the joint motions required for a given commanded tip motion the DR will be able to intelligently correct motions if it is perturbed by deflections of the flexible DR GA system In effect the DR need to Register its workspace determine
257. unctional flow is represented by nested numbering and by the indentation of the lines Please note that this information is presented textually instead of in block form We decided to leave it like this because it was easier to maintain and update the functional flow in text and producing blocks from this large a set of steps would take a large number of hours while adding little actual content to this section Appendix 1 1 1 Launch Phase Functional Flow 1 Launch 1 1 Pre launch system check 1 1 1 DR stowed in fixtures on EM 1 1 2 Keep alive power connection activated 1 2 DR enter keep alive mode 1 2 1 Shut down Actuators 1 2 2 Shut down Sensors 1 2 3 Shut down Communications 1 2 4 Shut down Processors 1 2 5 Activate Thermal Control Loop Appendix 1 1 2 Pursuit Phase Functional Flow 2 Pursuit The DR is in keep alive mode during this phase Appendix 1 1 3 Proximity Phase Functional Flow 3 Proximity Operations The DR is in keep alive mode during this phase Appendix 1 1 4 Capture Phase Functional Flow 4 Capture The DR is in keep alive mode during this phase Appendix 1 1 5 Approach Phase Functional Flow 5 Servicing 5 1 Deploy DR 5 1 1 Activate GA 5 1 2 Move to DR stow site 5 1 4 Grapple DR 5 1 4 1 Move arm until GF inside capture envelope 5 1 4 2 Grapple manipulator to DR GF 5 1 4 3 Verify physical connection was made 5 1 4 4 Rigidize connection and engage power data connectors 5 1 4 5 Signal successful connec
258. uous intermittent direction efficiency without motor operation operation of rotation motor GNM 5440 M max M max max reversible Kg Ibs mm in Nm oz in Nm oz in 5 6 1 1 0 2 20 251 9 88 2 7 382 3 13 1 841 85 9 33 1 1 0 2 20 251 9 88 2 8 396 5 13 1 841 85 14 5 1 1 0 2 20 251 9 88 3 8 538 1 13 1 841 82 17 1 1 0 2 20 251 9 88 4 2 549 8 13 1 841 78 30 1 1 0 2 20 251 9 88 8 1 133 13 1 841 72 35 1 1 0 2 20 251 9 88 8 1 133 13 1 841 69 For notes on technical data refer to Technical Information Specifications subject to change without notice MME0402 MicroMo Electronics Inc 14881 Evergreen Avenue Clearwater FL 33762 3008 Toll Free 800 807 9166 Fax 727 573 5918 info micromo com gt www micromo com ENGEL Series G2 6 amp G3 1 Dimensional outlines for 3150 G2 6 300 11 811 179 2 402 Dimensional outlines for 5440 G3 1 7 047 GNM 3150 G2 6 2x Front View me 10 O99 394 KEY DIN 6888 3 3 7 9 66 000 4X M5 6 236 DEEP 23 906 38 1 496 39 1 535 826 3g 115 1 142 m 1 969 E 591 L 251 3 071 9 882 GNM 5440 G3 1 4x M6 7 276 DEEP 2x11 433 Front View 2x 25 5 1 004 MicroMo Electronics Inc 14881 Evergreen Avenue Clearwater FL 33762 3008 Toll Free
259. upply Vpp A typical connection configuration is shown in figure 4 For Von less then 1 4V it is recommended that Vpp is connected directly to Vrece connected For Vpp gt 1 8V then the configuration shown in Figure 4 should be used registers are marked in bold and underlined like IntRq Bits Flags in registers are marked in bold only like SLEEP 06 04 Rev B Copyright O 2004 EM Microelectronic Marin SA 8 www emmicroelectronic com 52 5 Finally Cube camera with Progressive Scan and VGA resolution Incredibly small the IK 52V and K 53V deliver better results than cameras twice their size Imaging Video Products Group TOSHIBA The Toshiba IK 52V and IK 53V combine non interlaced Progressive Scan imaging with ultra compact dimensions for superior performance in a wide range of quality sensitive applications Progressive Scan VGA output to frame grabber or direct to a VGA Monitor 1 60 sec Non Interlaced Measures only 29mm square Weighs 46g 1 59 oz 1 3 inch IK 53V and 1 2 inch IK 52V CCD formats C Mount Lens Mount 659 H x 494 V resolution 1 lux F1 4 sensitivity 60 dB S N Ratio 52 5 3 12 VDC 10 5VDC 15VDC Power Consumption 120mA DC 12V Image Sensor IK 52V Progressive Scan 1 2 inch CCD IK 53V Progressive Scan 1 3 inch CCD Effective Pixels 659 H x 494 V Ho
260. uts torque and force at each joint Psuedocode Loop Read torque force data from t F sensors Apply 6D jacobian 1 to calculate force and torque at each joint Output data to motor command calculator 1 1 4 Report data to Overload monitor module 1 1 6 end loop 1 See appendix 8 for the 6D jacobian Function Command interpreter 1 1 3 Inputs Data input scripted motor control data Data input Earth Control command for motors Data input Emmergency commands Outputs destination position and velocity Psuedocode Loop Check for emmergency halt commands Check for command from Earth control Get required motor position data from script Tf Emmergency halt command exists forward to command control module Else if Earth command exists it overrides scripted command Else Pass on scripted command to motor command calculator End loop Function Motor command calculator 1 1 4 Inputs Data input Command from interpreter 116 Data input motor shaft position from encoder Data input force torque on each joint Data input Power availability State data overload status State data motor health Outputs PWM values for each motor Psuedocode Loop Acquire overload status If overload Shutdown motor Else Acquire command from interpreter 1 1 3 Acquire motor position velocity T2523
261. ving constraint for the arm it is necessary to have the both precise and simple to control actuators A tendon driven arm will be far too flexible for the DR application and for this reason a tendon system is ruled impractical 8 6 2 Booms 8 6 2 1 Same Arm Sizes vs Differing Sizes While it is possible to operate such that one arm performs the more structurally demanding tasks while another does only fine manipulation doing so increases mission risk in the event of one arm experiencing a failure By having two arms with identical performance envelopes many operations can be performed by either arm 69 8 6 2 2 Straight vs Tapering Consistent size allows for simpler manufacturing and analysis as well as providing consistent paths for routing cables etc By maintaining a maximum diameter along the length of the arm the second moment of area and thus stiffness is maximized 8 6 2 3 Carbon vs Aluminum The loads on the booms of each arm can be easily withstood by all of the suggested space materials and so we make the choice of carbon based on secondary criteria Carbon fiber composites have excellent mechanical properties including high stiffness low density and extremely low coefficients of thermal expansion A low CTE is desirable in reducing end effector positioning error due to thermal drift While composite structures are harder to manufacture than metals the demands of the DR do not require any exotic structural design outs
262. w and details are provided in Appendix 6 6 Connector 1 Connector 2 Total Pins Low Power 115 V 8 8 16 High Power 24 V 10 10 20 1553 Data Bus 4 4 8 Video Line 4 4 8 Sensors RS232 4 4 8 LCS RS422 2 2 4 Pin Total 32 32 64 Table 3 1 GA DR Electrical Interface Requirements A trade off that has been considered is to have 4 connectors a connector for the primary power a connector for the back up power a connector for the primary data and a connector for the back up data This has the advantage that it is more than single fault tolerant and that if one connector fails for any of the power or data the other connector can take over while the second system would still have two connectors for use The disadvantage with this is that it would greatly tighten the mating envelope and hence increase the accuracy requirement of the mating It has been deemed unnecessary and so it has been decided that two connectors are sufficient each with a full power and data system All separate structures for the GA and DR will be electrically linked to provide a common ground We assume that the GA structure will be electrically linked to the EM structure so that the DR structure will also be the same potential as the EM structure and hence will not cause a shock upon contact when retrieving WF PC2 or WFC3 173 4 Software Interface 4 1 Coordinate Systems The origin of the DR coordinate system will be locate
263. w away tools and parts not in use The DR motion should have a resolution of 0 1 inch and 0 1 degree The DR motion should be accurate to 1 degree and 1 inch The DR must be able to stop 100016 mass from the maximum commanded tip velocity within 2 inches and 2 degrees Ui O 1 SS 8 3 1 3 Design and Performance The tool arm will be able to achieve a tip speed of 0 04 m s 2 s when maneuvering a 1000Ib payload and can move faster when moving smaller loads Table 8 1 lists the DR tool arm characteristics and the details are found in Appendix 8 3 59 Main Boom Lengths 0 85 m Arm Diameter 0 15 m Arm Offset from Body Center 0 45 m Total Arm Length 2 6 m Tip Translation Speed 1000 Ibs 0 04 m s Tip Rotation Speed 1000 Ibs 2 ls Mass structure and motors only 138 6 kg Table 8 1 DR Tool Arm Characteristics The material selected for the arm was carbon composite The arm will have six degrees of freedom to be able to perform its tasks Motors and gears performance for the tool arm is summarized in Appendix 8 3 7 The calculations were based on satisfying the requirements imposed on the tool arm Our design utilizes two gearboxes coupled together to provide the appropriate output speed and torque required The motor is attached to a primary worm gearbox which is inherently nonbackdrivable the ramifications of this are discussed below The output shaft of this box is then coupled to a secondary planetary
264. will be 20 30 67 This allows moderate power consumption when the heaters are on and also leaves room to increase our power need by increasing our duty ratio Increasing the duty ratio may be required because of degradation of the heaters or unexpected cold cases amp heat loss A total of 18 heaters are needed This comes from needing 14 heaters to be evenly distributed among the joints 7 heaters on each arm and 4 on the body Each heater will be approximately dissipate 1 7 W when on 8 4 Fault Tolerance The fault tolerance requirement is to be single fault tolerant While we have done so in most subsystems it is unfeasible to fully meet the requirement mechanically Adding an extra tool arm or an extra body would have been analogous to carrying an extra engine in a car to make the car single fault tolerant Our calculations have a high safety factor of 1 75 and we believe that well manufactured gearboxes and motors should eliminate the need to double the number of gearboxes and motors The booms can be made sufficiently strong to prevent buckling or any mechanical failure during the mission 67 8 5 Mass Budget A detailed mass budget for the DR may be found in Appendix 8 7 For those components for which the mass was difficult to estimate a number of assumptions had to be made These are outlined and justified below 8 5 1 Cabling and Connector Mass These figures were generated from a previous analysis of the cabling mass for the
265. wire 2 Else I bundle I wire 29 N 28 Adjust wire gage until I bundle gt I req Mass R radius of the wire plus insulation L circuit length Rho density of copper 8960 kg m 3 t shielding thickness R_bundle bundle radius N_drops number of bus drops M_drop mass per drop M bus pi R 2 L rho N 138 M bundle sum M bus M shielding t 2 pi R bundle L rho M bus drops n drops m drop M total M bundle M shielding M bus drops Appendix 7 4 3 Data Cables circuit wire Insulation bundle of bundle 4 wires mass kg Tool Arm Bundle 0 404 050 011 0404 050 009 0404 050 009 12 4722 21 Body Bundle Bus D3 1553 0 404 0500 006 Bus 05 1553 oaoa 0 500 0 05 Tool Arm Bundle 0404 050 011 0 404 0500 0 09 0404 050 002 De ULL 139 thickness side mass number of mass mm kg bus drops kg kg Tool Arm Bundle EC a EC O T T paT To BusVi Vieoc 2 To Bus V2 Video 2 __ 00st 4 99 Body Bundle Busp3 153 Busps 153 W 2 0031 12 99 Tool Arm Bundle BusD4 1559 BusV3 Video BusV4 Vilo 2 _ 03 Poort 36 995 Appendix 7 4 4
266. xagonal female interface The ground strap release tool will have end dimension less than or equal to 1 25 in diameter in order to clear the surrounding structure when turning The ground strap release tool will interface with the tool end effector on the DR e The RSU connector tool will grapple the terminator plugs The RSU connector tool will securely hold the terminator plug while moving it to new location The RSU connector tool will interface with the tool end effector on the DR The diode box connector tool will grapple the P6A P8A connector The diode box connector tool will be able to rotate and unscrew the P6A P8A connector The diode box connector tool will securely hold the P6A P8A connector while moving it to new location The diode box connector tool will interface with the tool end effector on the DR The harnessing tool shall to fix the conduit in place securely The ground strap stowing tool will need to stow the ground strap temporarily The clip tool shall have a target for the DR end effector to locate 8 3 4 3 Design and Performance Specifications Un powered tools were chosen in order to eliminate the need for an electrical interface between the end effector and the tools Since no connectors need to be mated the accuracy involved in the tool capture procedure is reduced Furthermore the tools themselves become much less massive as no motors electronics or cables are housed in them The wrist roll joint will pr
267. y and backup for each electrical unit If necessary regulators drop the bus voltage to that required by the electronics In addition the voltage regulators ensure the input to electronics is within their specified limits by increasing or decreasing the voltage by small amounts as required 7 2 3 4 EMI Filters EMI filters are used in the electrical units of the motors and the LCS These components are noisy and in order to prevent propagation of this noise into the rest of the system EMI filters are used 7 2 3 5 Analog to Digital Converters These are used to convert analog data from various sensors to a digital signal that can be received by a micro controller 7 2 3 6 Collision Avoidance Sensors The collision avoidance sensors will be located near each electronics box MEU with each box providing the required data and power connections In this way a separate connection to the power and data bus is not required The redundant hardware in each electronics box will support its own collision detection system Since each collision detector is composed of an IR emitter 51 and detector both of which are small and consume little power it is acceptable to have a redundant collision system on each joint to correspond to the redundant hardware busses 7 3 Electrical System Implementation 7 3 1 Power Busses 7 3 1 1 Interfaces The power for the DR is transferred from the EM via cables through the GA Two 20 pin power connecto
268. yr in terms of 4 1 18592 10 e 13 232 s 23 b Energy Balance for DR during the hot case ernal max heating Q pR MLI or 30 d heating pre MILI 330 1 7181 107 159 using equation a for we can get an expression for heating terms Of 5 g DR _ 796 0862 ne 30 d heating Epr 23 for 0 lt 1 Gheatingmax 3 17 W for 5 71 Gheatingmin 30 W for 0 i e need to cool off 30 W Energy balance for cold case a Requiring that Tprmin 273K we have the energy balance for MLI blanket to be d s min d a min d iR min Q emitted 4 xT DR 475 19 392 66 Epes 273 Tu 1 7181 107 1 7181x107 surface surface which becomes 4 273 ey 11 9511 Ta Ep F23 b Cold case energy balance for DR heating Mu x1 7181x107 Using a for cold case we get 24217796 heating E 23 for 0 lt EDR lt l Qheatingmax 17 57 W for pg 1 Gheatingmin 0 W for DR 0 To sum up we have the following heating requirement range based on our equations Hot case qheating needed Cold case qneating needed Epl 3 17 W 17 57 W Epp 0 30 W 0 W Picking a high emissivity for DR we can design it such that we do not get 30 W i e we do not use a cooling system If DR was also painted white such that 0 92 then qneating
269. ystem is single fault tolerant 4 3 1 1 5 Imaging system may include stereoscopic cameras or LIDAR 4 3 1 2 6 The vision system shall have stable supporting software algorithm able to resolve the DR pose regardless of its configuration 4 3 1 2 7 The vision system shall be capable of providing real time feedback the CD amp H system to facilitate closed loop positioning and semi autonomous operations 4 32 The DR shall have the ability to perform operations directly under Earth Control 4 3 2 1 The DR CPU shall be capable of receiving scripted ground commands through the EM to control DR operations 4 3 2 2 The DR CPU shall be able to send visual and position data feed back to ground control from data fed back to it from DR via the EM comm 4 3 2 3 The DR shall feedback data applied torque and force as felt at end effector video and position to GC to assist in Ground Control feed back 4 3 2 4 The DR actuators shall be able to follow ground commands with the accuracy as found in 4 2 1 4 3 2 5 The Vision System on DR shall be of sufficient resolution to provide enough details for efficient ground control 88 4 3 3 The tools shall be capable of properly interfacing with the DR as well as all the required interfaces on HST 4 3 3 1 All tools will have two interfaces 4 3 3 1 1 Interface with one of the DR end effector ideally the same in all the tools 4 3 3 1 2 Interface with the appropriate part of the HST or the component it is

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