Autonomous Self-Extending Machines for Accelerating Space Exploration
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1 Autonomous Self-Extending Machines for Accelerating Space Exploration NIAC CP Phase I Hod Lipson, Evan Malone Cornell University Computational
2 Motivation Robotic exploration has a long cycle time Better propulsion Mission goals are inflexible Design more complex robot Failure is catastrophic Make more stringent reliability testing Vicious circle of cost and complexity
3 Concept Remote autonomous fabrication of complete functional systems Design after launch (shorter cycle) Less commitment (more flexibility) Task specific robots (less complex) Repair and recycle (reliability less critical)
4 Prior concepts Self replicating lunar factories It more efficient to send information in preference to matter Ambitious future missions can be greatly shortened through remote factories Self-extending facilities can have much more flexibility Advanced Automation for Space Missions, Robert A. Freitas, Jr. and William P. Gilbreath, editors.
5 Our concept Fabrication system that is Compact Fully autonomous Can fabricate fully functional systems Can build systems larger than itself Can build repair / extend itself High gain fabrication system: SFF
6 SFF: Two architectures Comprehensive Can make anything Has every conceivable fabrication method Catch: Shifts the cost and reliability to SFF Minimal Has a minimal spanning base of materials Cannot make all things, but can achieve any functionality Catch: Requires re-parsing of design in terms of available capabilities
7 Example: Computational A possible minimal architecture Articulated arm SFF structure, actuation, sensing, power, control, recycling Assembly Multiple identical arms cooperate Redundancy Self repair
8 Summary of proposal Analyze missions requirements Consider a variety of destinations Survey available and foreseeable SFF technologies 1. Provide roadmap to alternative architectures 2. Evaluate architecture through limited implementation
9 Background on SFF Introduction to Solid Freeform Fabrication State of Solid Freeform Fabrication Today Materials Processes Products Markets Developmental trends
10 Commercial SFF Processes Fused Deposition Modeling (FDM) Laminated Object Modeling (LOM) Stereo Lithography (SLA) Selective Laser Sintering (SLS) 3-D Printing / Multijet Modeling Laser Direct Metal Deposition (DMD / LENS)
11 Research in SFF Processes Piezo actuators / sensors via LOM, SLS, FDC/FDMM, including electrodes (Rutgers) Fabrication of SiC / C thermocouples on Al 2 O 3 ceramic, and welding (CVD) of ceramic via SALD (U.Conn.) Universality by CMU/Stanford SDM Passive circuit elements by laser processed sol-gel materials (Sciperio) DMD of on-demand spare parts in space FDM in zero-g (Vomit Comet) Focused Solar Sintering / OW Electron Beam SFF
12 Future of SFF in Missions Near-term, near Earth: Spares on demand / inventory reduction for ISS too easy (for NIAC!) and already underway Mid-term, Moon, Mars: Repair / extension of planetary landers / rovers, Preparation of facilities / resources for manned mission Long-term, Outer planets, beyond: Very distant scientific missions Essential component of indefinite duration robotic mission / self-replicating robotic ecosystem
13 Mission Requirements What do these missions require of a fabrication system? Produce Functional Components / Functional Systems Compact size, low mass Energy efficient Large functional gain / small set of inputs Simple, robust, and safe system Tailored for use of in situ resources and products of ISRU and recycling Fully automated, high yield process
14 Example: Architecture for MARS Atmosphere Recycled Components, Materials Non-SFF-ables Feedstocks Obsolete/Damaged
15 Two thrusts of development #1: Universality of the fabrication process Commercial development of SFF processes for mass customization What is not likely to be achieved by commercial efforts? Process integration, compaction (too many proprietary, no motivation) Basis sets of materials / ISRU focus Production of fully functional systems in SFF style 100% automation
16 Two Thrusts of Development #2: New design paradigms: Design for Solid freeform fabrication of fully functional systems (different components, multi-materials, wild geometry) Use of In situ resource feedstocks Highly constrained material selection Automated recycling / reuse Automated assembly / disassembly Automated extension / replication
17 Design Process for Fabricator Mission Specification Mission Mission Functionality Model Specification of functionality desired as decision tree - depending on time, discovery, etc. Resources Model Expected In situ raw materials Expected energy sources (solar,etc.) Expected temperatures, pressures, radiation, etc. Earth-originating resources, components, etc. Earth-based computational resources Mission Earth-originating mass limitation Recycling Technology Model Mapping from set of input feedstocks (including power) to set of output products Intrinsic properties of recycling systems Manufacturing Technology Model Mapping from set of input feedstocks to set of output products Intrinsic properties of manufacturing systems Design Automation Tools Evolutionary algorithmic methods Design Paradigms Simulation Projected Mission Design Projected Achievable Functionality Result of constrained automated design Projected Resource and Technology Utilization Technologies employed by simulated mission Resources consumed in simulated mission ISRU Technology Model Mapping from set of input raw materials to set of output materials Intrinsic properties of ISRU systems Analysis Identify essential missing technologies Identify binding mission constraints
18 Technology Evaluation Platform Small scale, 6 axis industrial robot arm Multiple tools Linear motor driven hot extruder for thermoplastics (polypropylene) Pneumatic dispenser for conductive grease, silicone RTV elastomer Hot pneumatic dispenser for low-melt alloy Automatic part slicing and path planning software
19 Progress Automatic tool changing Tool control Multiple tools means many processes to refine and control Using OOP to simplify interface Hardware is very heterogeneous Path following: planar raster paths for now All the pieces are working together!
20 System
21 Dispensers
22 Results
23 System in Action
24 Near Term Goals SFF Actuators Electroactive Polymer Actuators Extruded solenoid Power storage Printable Zinc-air battery Controls / Electronics Mechanical switches Resistors Capacitors Build minimal functional mobile robot!
25 Conclusion / Recommendation Solutions foreseeable for structures, articulation, actuation, conduction Key Challenges Develop SFF power storage, control logic Integrate basis set of processes into compact system Develop design paradigms for SFF, complete functional systems Our role and plan Seek functional universality 100% automation Fabricate entire functional robot
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