Pg 1 Robonaut TIR Overview September 15, 2010 Beth Griggs Robonaut Ops Lead

Pg 2 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

Pg 3 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.

Pg 4 Hardware – Station Support Equipment –UOP Cable Assembly (SEG ; 14’ cable) –PEEK 120 VDC 12 AMP 10' Extension Cable (SEG ) –Ethernet Cable (1F x) –USB Speaker Cable (SEG ) –Unbalanced BNC Cable (SED ) –Advanced Video Interface Unit (SED ) –Internal Camera Port (ICP) Interface Cable (SEG ) –Multiuse Bracket Assembly (SEG ) –Velcro Straps (P/N 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 (SEG )

Pg 5 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.

Pg 6 Robonaut Torso Baseplate Task Board Softgoods Task Panel Stanchion (w/ softgoods cover) Stowage Configuration (continued)

Pg 7 Deployed Configuration on ISS Operations 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.

Pg 8 Robonaut Free space Ops – INC 26 OperationObjectiveCrew/GroundNotes/Constraints Stowage ConfigurationRemove Robonaut from launch container & stow in LAB1P1 CrewEmpty 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 TBDGround and CrewTBD

Pg 9 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.

Pg 10 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.

Pg 11 Robonaut – Data Pathway

Pg 12 JSC TSC PAYCOM CAPCOM FD Robonaut Control* (Admin PC) ISS Crew POD Robonaut Lead Robonaut (US Lab) Command & Telemetry via JSL Voice I/F Robonaut Task * Robonaut Control console may be required to support from MER for initial ops Proposed Real-Time Ops Concept

Pg 13 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)

Pg 14 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 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.

Pg 15 Robonaut Operational Hazard Controls 1Structural 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 2Structural 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, 3Shatterable 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. 4Fire HAZARD 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. 5Touch Temperature HAZARD DESCRIPTION: Robonaut external surfaces can approach temperatures of ~151 o F before the internal temperatures reach the thermal limits of the electronic components. HAZARD CONTROLS:Operating time will be limited for Robonaut.

Pg 16 Robonaut Operational Hazard Controls 6 Electrical Shock HAZARD 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. 7Interference with Rapid Egress HAZARD 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. 8Uncommanded 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. 9Release 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. 10Inadvertent 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..

Pg 17 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.

Pg 18 Back-up Slides

Pg 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

Pg 20 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

Pg 21 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

Pg 22 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