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Robonaut TIR OverviewSeptember 15, 2010

Beth GriggsRobonaut Ops Lead256-961-1926

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Hardware – Robonaut and Associated Equipment

• A Robonaut Upper Torso for use as a robotics testbed on ISS. Upper Torso includes:– Head– Arms– Waist Joint– Backpack Power Supply– Motion Stop Controller

• Mechanical Interface to ISS– Baseplate interface to Rack Seat Track– Stanchion interface between Torso and

Baseplate• Task Board with task panels

– Reconfigurable mounting board for Robonaut experimental tasks

• Switches, connectors, handrails, etc.

Robonaut

Baseplate and Stanchion

Task Board with Task Panels

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Hardware - SLEEPR

Integration into SLEEPR/Clamshell (Structural Launch Enclosure to Effectively Protect Robonaut)

• SLEEPR mounted on starboard side of PMM and protrudes into aisle• Five struts secure Robonaut inside• Forty captive screws have to be removed from back panel. Four bolts and a screw must be loosened to remove Robonaut from dovetail fitting on base of SLEEPR.• SLEEPR will be discarded without further disassembly and can only fit in HTV2 – this may mean we can’t remove Robonaut from SLEEPR until HTV-2 arrives.

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Hardware – Station Support Equipment

– UOP Cable Assembly (SEG33108825-305; 14’ cable)

– PEEK 120 VDC 12 AMP 10' Extension Cable (SEG33112596-301)

– Ethernet Cable (1F15940-50x)

– USB Speaker Cable (SEG12100669-801)

– Unbalanced BNC Cable (SED33105779-301)

– Advanced Video Interface Unit (SED33111493-303)

– Internal Camera Port (ICP) Interface Cable (SEG16103296-301)

– Multiuse Bracket Assembly (SEG33107631-301)

– Velcro Straps (P/N 528-43074-X, different lengths)

– Handrail Equipment Anchor Assembly (HEA) (G11F5121-1)

– Seat Track Equipment Anchor Assembly (STEA) (P/N TBD)

– SSC (Station Support Computer) T61P Laptop (SEG33120761-301)

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MO-3 Bottom

MO-1 Bottom

Stowage Configuration

• Robonaut and the support hardware will be stowed in an MO1 and MO3 bag within the LAB1P1 location when not in use

• The MO1/MO3 bags will be tethered via bungee/velcro ties in the empty rack bay. These procedures are in development.

•This stowage configuration has been coordinated with OZ, ISS Stowage and Topology groups.

•Procedures will need OSO review.

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Robonaut Torso Baseplate

Task Board

Softgoods Task Panel

Stanchion (w/ softgoods cover)

Stowage Configuration (continued)

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Deployed Configuration on ISSOperations

LAB1D2

LAB1P2

Inc 27 will likely progress into Task Board operations.

Inc 26 will likely only entail Free Space operations.

Robonaut will be mounted to LAB1P2 for Free Space AND Task Board ops.

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Robonaut Free space Ops – INC 26

Operation Objective Crew/Ground Notes/Constraints

Stowage Configuration Remove Robonaut from launch container & stow in LAB1P1

Crew Empty LAB1P1 location, OSO Transfer from PMM complete

Robonaut On-Orbit Soak

Power on Robonaut, establish comm, monitor telemetry, verify functionality. Determine response to 0-G.

Mainly ground commanding. Crew will need to physically flip switches, provide feedback on hardware.

SSC Load with Robonaut SW must be completed; No Robonaut Movement, cabin video required

Robonaut Safety Checkout

Verify Safety Controls are place

Mainly ground commanding, crew needed to physically maneuver limbs, provide feedback on hardware.

Limited movement; cabin video required; ground controlled

Robonaut System Checkout

(may be repeated several times for various tests)

Verify vision capabilities, test joint range of motion

Mainly ground commanding, crew needed to physically maneuver limbs, provide feedback on hardware.

Head, limb and single joint movement, ground controlled. cabin video required

EPO or PAO Opportunities

TBD Ground and Crew TBD

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Robonaut – ISS Interfaces

• Structural:– Baseplate, Stanchion, Robonaut will be mounted to LAB1P2– Task Board when in use will be mounted to LAB1D2

• Power:

– 120 VDC from UOP. Power will come from UOP1 and will use a PEEK 10 foot extension cable and a 14 foot power cable.

• Data:– Joint Station LAN (JSL) (Connected to UIP at Lab1D1) (GigE Video)

• Thermal:

– Robonaut is cooled by forced air flow from fans within the robot and the backpack, therefore interfacing to the cabin air

• Video:

– TeleOps Video will require the standard Lab Cabin Video Pathway (AVIU US Lab ICP (Internal Camera Port) CVIU (Common Video Interface Unit) etc

– Node 2 Cabin Video – Positioned to face into US Lab to “see” Robonaut, must use the Node 2 camera because the lab cabin video interface is needed for TeleOps Vision.

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Robonaut – ISS Interfaces

• Telemetry:– Require “Near Real-time” downlink of Robonaut data

• Bandwidth: No lower than 100kbs

• Robonaut raw data will be captured off OCA LAN on a new workstation (Robonaut Ground Workstation) in MCC next to Admin PC

– Admin PC Usage

– Require Admin PC access to Remote Desktop into on-board ISS SSC Client.

– Remote Desktop session will be used to control the Robonaut GUI program on ISS SSC Client to remote control Robonaut.

– ISS OCA PC Usage

– Require OCA PC to uplink new config files or edited script files as necessary to ISS SSC Server.

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Robonaut – Data Pathway

UIPEDGE ROUTER

OCA Ground Router

OCA STATION ROUTER

ROBONAUT

TD

RS

ADMIN PC

GROUNDISS US LAB

15m Ethernet CableP/N 1F15940-503

SSC Client(w/ Robonaut GUI and Vision S/W )

SSC Server(w/ Robonaut FTP)

Remote Desktop Control and Data Pathway of Robonaut

Motion Control and Vision

Boot-Up and Data Files

MCC/Houston

OCA Ground Switch

Telemetry Data, Vision and Log Files

Remote Desktop to SSC ClientUpload Robonaut Data Files

Physical Connections

Data FlowRobonaut

Workstation (setup by FDOC)

UIPEDGE ROUTER

OCA Ground Router

OCA STATION ROUTER

ROBONAUT

TD

RS

ADMIN PC

ADMIN PC

GROUNDISS US LAB

15m Ethernet CableP/N 1F15940-503

SSC Client(w/ Robonaut GUI and Vision S/W )

SSC Server(w/ Robonaut FTP)

Remote Desktop Control and Data Pathway of Robonaut

Motion Control and Vision

Boot-Up and Data Files

MCC/Houston

OCA Ground Switch

Telemetry Data, Vision and Log Files

Remote Desktop to SSC ClientUpload Robonaut Data Files

Physical Connections

Data FlowRobonaut

Workstation (setup by FDOC)

Robonaut Workstation (setup by FDOC)

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JSC TSC

PAYCOMCAPCOM

FD

Robonaut Control*(Admin PC)

ISS Crew

POD

Robonaut Lead

Robonaut(US Lab)

Command & Telemetryvia JSL

Voice I/F

Robonaut Task

* Robonaut Control console may be required to support from MER for initial ops

Proposed Real-Time Ops Concept

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Robonaut – Potential Scheduling Conflicts

Due to the size of Robonaut there are several scheduling guidelines and constraints. The following crew-tended operations shall not be scheduled concurrently:        - Avionics-2 (LAB1D1)         - Avionics-2 (LAB1D2)         - WORF (LAB1D3)         - ER-1 (LAB1O2)         - ER-2 (LAB1O1)         - MELFI-2 (LAB1S1)         - MSG (LAB1S2)         - CIR (LAB1S3)         - MSRR-1 (LAB1O3)        - ER-7 (LAB1P2)         - FIR (LAB1S4)         - PPFS (LAB1P2 and LAB1P3) deployed         - SPHERES (aisle bays 1-3)

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Scheduling Constraints

•The PSRP specified a thermal constraint and has limited Robonaut to 2.2 hours from power up to power down.

•Operations will only occur in the US Lab.

•Robonaut must be stowed in non-flammable MO-3 bag when not in use. A small portion of "skin" (elbow joint, shoulder joint, portions of glove at wrist) are made of Lycra which is flammable.

•PEI included the following in PIRN 57238-NA-0004: “Robonaut shall not come within 6 inches of any rack face during operations except during ops requiring the Task Board”. However, the PD team has stated they will not sign this PIRN since the PSRP never levied the requirement.

•MSG Stray light cover will be deployed during Robonaut ops to prevent scratching the Lexan window in case of Robonaut failure.

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Robonaut Operational Hazard Controls

1 Structural Failure HAZARD DESCRIPTION: Structural failure of the robot

HAZARD CONTROLS: Closed volumes inside Robonaut have been assessed to verify that no hazard will result if exposed to a depressurization event

2 Structural Failure of Support Hardware

HAZARD DESCRIPTION:

Structural failure of Robonaut Stanchion, Baseplate, or Task Board could release a large mass, causing injury to the crew or damage to ISS hardware, and inability to properly react applied loads could transmit excessive force to ISS Rack mounting structure causing damage to vehicle hardware.

HAZARD CONTROLS: Robonaut Support Hardware is designed to withstand worst-case launch or on-orbit loads,

3 Shatterable Material HAZARD DESCRIPTION: Robonaut camera lenses are made of glass

HAZARD CONTROLS: The lenses are protected by Robonaut’s face plate and are not subject to loading.

4 FireHAZARD DESCRIPTION: Robonaut contains flammable materials

HAZARD CONTROLS: Robonaut is to be stowed in its non-flammable bag when not in use and kept away from ignition sources.

5 Touch TemperatureHAZARD DESCRIPTION:

Robonaut external surfaces can approach temperatures of ~151oF before the internal temperatures reach the thermal limits of the electronic components.

HAZARD CONTROLS: Operating time will be limited for Robonaut.

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Robonaut Operational Hazard Controls

6  Electrical ShockHAZARD DESCRIPTION: Electric components pose a shock hazard.

HAZARD CONTROLS:Conductive surfaces are double-fault bonded and grounded to Station ground. The braided shield on the power cable provides a secondary ground path.

7 Interference with Rapid EgressHAZARD DESCRIPTION:

When installed, Robonaut does not obstruct the translation path through the US Lab

HAZARD CONTROLS:In the event of an emergency requiring the crew to exit the module, Robonaut can be removed within 30 seconds using quick release mechanisms.

8 Uncommanded Motion / Excessive Force HAZARD DESCRIPTION:

Robotic operations in the location of crew members and nearby equipment carries the inherent risk of crew injury or hardware damage

HAZARD CONTROLS:Robonaut is designed with a robust control architecture that prioritizes human safety. Robonaut has multiple independent controls against exerting excessive force, and it is designed to safe itself in the event of system errors.

9 Release of Toxic Fluid from Capacitors HAZARD DESCRIPTION:

Robonaut uses various sizes of aluminum electrolytic capacitors. The electrolyte has been assessed as THL 1, requiring 2 levels of containment.

HAZARD CONTROLS:

Absorbent material has been added to mitigate any electrolyte release. All capacitors are enclosed within either the robot body or the backpack and are not accessible to the crew. In addition, the components are used below their rated voltages, reducing the risk of failure.

10 Inadvertent Release of Tools HAZARD DESCRIPTION:

Robonaut may use different hand-held tools when interfacing with the Task Board.  

HAZARD CONTROLS:

Release of these tools could create a hazard, so larger tools will be tethered or crew tended. .

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OTHER ITEMS OF NOTE

• The SSC Integrated Load V 4.0 that includes Robonaut software must occur prior to ops. (expected early Dec 2010)

• Robonaut joints (wrist, elbow, shoulder) are covered with flammable lycra, thus the requirement for the MO-3 Bag.

• A hand-held Motion Stop button will have velcro patches and a 20’ cable such that it can be affixed beyond Robonaut’s max reach.

• Since Robonaut will be controlled from the PLUTO workstation at JSC, schedulers will need to ensure that scripts can be complete before LOS. We will not ask the crew to operate during LOS.

• Since PLUTO does not staff weekends, Robonaut is not a candidate for Vol Science.• Robonaut must use SSC Server 1.• There may be a required wait after the SOAK for data analysis before the SAFETY

and SYSTEMS checkouts can begin. However, feedback should be instant from the checkouts.

• Cable connections are located at the bottom of the Backpack with labels stitched on the soft cover. During setup, the crew has to create a 40” service loop of cables to allow Robonaut to have 225 degree rotation.

• All cables except the Motion Stop Controller are Common Use Station hardware and are shared.

• A JOIP is being developed to document coordination between POIC, the Robonaut team and MOD.

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Back-up Slides

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• 6061 Aluminum– ~30 lbs– 19” x 41.25” x 6.36”

• Task Board Frame is black anodized for maximizing fiducial contrast

• 6 fiducials• Holds 4 removable sub-panels

• ¼ turn fastener interface• 1” x 2” Velcro squares with seat track section• Attaches to rack seat track via threaded knobs

Task Board

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Task Board Panels

• 6061 Aluminum– Clear anodized– ~ 5 lbs– 8.65” x 12.65” x 4.31”

• 5 Sub Panels in work– IVA Task Panel – Un-powered– IVA Task Panel – Powered– Hardware stowage panel– EVA task panel– Softgoods panel

• Attached to task board frame with 4 quarter turn fasteners

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Baseplate

• 6061 Aluminum– ~57 lbs– 22” x 41.25” x 4.26”

• Dovetail Design Concept– Allows for horizontal adjustment– Low profile

• Attaches to rack seat track with threaded knobs

• Qty 2 fiducials

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Stanchion

• 6061 Aluminum– ~22 lbs– 9” x 9” x 26.06”

• Dovetail Design Concept– Allows for horizontal adjustment

• Spring plunger interface provides discrete locations along the baseplate

– 2 threaded knobs provide clamping force for dovetail joint

• Installs in either orientation– Symmetric

• Includes stanchion cover– Softgoods cover