test readiness review - illinois space society...

Illinois Space Society 1

Test Readiness Review Illinois Space Society (ALMA)

The University of Illinois at Urbana-Champaign


Illinois Space Society Team

Sara LeggAerospace Engineering

Project Manager

Destiny FawleyAerospace Engineering

Safety Lead

Courtney LeverenzAerospace Engineering

Educational Outreach Lead

Ryan NoeAerospace Engineering

Manufacturing Lead

Megan GeyerAerospace Engineering

Testing Lead

Michal SilezinAerospace Engineering

Design Lead

Return to Table of Contents


Presentation Outline

1. Illinois Space Society Team2. Abstract and Background3. Challenge Requirements4. System Overview5. Design Overview6. Component Overview7. Safety8. Requirement Compliance9. Operations Plan10.Conclusion


Abstract and Background

Abstract: This TRR contains the finalized design of the ALMA tool created by the Illinois Space Society for its testing in the NBL.

Background:➢ Increased interest in the study of asteroids in order to reduce the amount

of fuel carried➢ NASA's Asteroid Redirect Mission and OSIRIS-REX Mission

Tool Application: To be able to grip/attach onto celestial bodies in microgravity. The tool can also be used in various types of environments depending on the internal structure of the celestial body.

http://referentiel.nouvelobs.com/file/15463902-exploitation-miniere-la-ruee-vers-les-asteroides-

acommence-cette-nuit.png


https://www.nasa.gov/feature/asteroid-redirect-mission-community-update/

http://referentiel.nouvelobs.com/file/15463902-exploitation-miniere-la-ruee-vers-les-asteroides-acommence-cette-nuit.png

https://www.nasa.gov/feature/asteroid-redirect-mission-community-update/


Challenge Requirements

➢ Challenge: To design and manufacture a device that can anchor onto a celestial body in microgravity.

➢ Requirements:– The device shall remain anchored in the simulants without the use of an operator.

– The device shall remain anchored in the simulants when pulled upward with a 15 lbf.

– Mass and volume of the device should be minimized.

– The device can be operated manually or under power. Powered operations shall be driven pneumatically.

– The device can have multiple parts that can attach and detach.

– The device (all parts, in stowed configuration) shall fit within a 10” x 10” x 18” volume.

– The device (all parts ) shall have a dry weight less than 20 lbs.

– The device shall be ambidextrous.

– The device and any removable components shall have a tether attachment point 1” in diameter.

– The device shall be compatible with a chlorine water environment.


ppt/slides/slide3.xml

ppt/slides/slide3.xml


ALMA System Overview

Courtney Leverenz



ALMA Overview

➢ The Adaptable Low-Cost Modular Anchor (A.L.M.A.) is an anchoring device that has been specifically designed to increase the ease of anchoring onto a surface in micro gravity through a ratchet mechanism.

➢ Rotating handles

➢ Auger cover

➢ Pull pin attachment

Ratcheting Section

Anchoring Section



ALMA Component Names

Ratchet Casing

Tether Point

Receiver

Tether Point

Auger Shaft

Auger Auger Cover

HandlePawl Shaft Main Shaft

Locking Levers



ALMA Basic Characteristics

➢ The ALMA tool meets all of the specified size and mass requirements as seen in the table and figure below.


• Weight with Auger Casing: 6.7393 lb.• Length: 17.616”• Auger Width: 8.00”• Auger Casing Width: 8.499” (with extrusions: 9.25”)• Shaft Diameter: 1”• Handle to Handle Length: 22.83”


Handle Mechanism

First, the diver will have to rotate the handle locking lever in order to loosen the handle hinge. Upon loosening, the diver will rotate the handle (~90 degrees) so it is perpendicular to the shaft. Once in the proper position, the diver can rotate the lever clockwise (yellow) to tighten the handle for use. When they want to loosen the handle, all they have to do is rotate counterclockwise (blue).



Ratcheting Mechanism Overview

With a counterclockwise rotation (4), the pawl is guided to lock into the next tooth.The following process goes along with the counterclockwise rotation.1. Pawl compresses spring.2. The pawl's shaft is rotated in order to

allow it to lock onto the next tooth.3. Once pawl has moved to the next

tooth, the spring locks it into place.



Shaft Attachment

➢ The gear is placed on the main shaft. The main shaft then locks into the receiver. The whole system is then locked together by screwing through the gear into the receiver.

➢ There is a hole on the shaft that locks into the receiver by a pull pin system. (RED)

➢ To ensure shaft is locked into place during rotation, a flat component is included in the receiver and on one side of the shaft. (BLUE)



Auger Cover Locking Mechanism

➢ Simple auger cover used for blade protection.

➢ Plastic cover with a strap across to retain the auger.

➢ The leading edge of the auger lies flush with the auger cover.



Design Overview

Michal Silezin



Design Inspiration


https://www.creativeshelters.com/content/52e9b

c415e007.jpg

https://www.creativeshelters.com/content/52e9bc415e007.jpg


Initial Auger Design Ideas



Progression of Design

Initial design: November 2016

First Iteration: December 2016

Second Iteration/Final Design: Jan/Feb 2017



Final Auger Design



Component Overview

Ryan Noe



Manufacturing Information

➢ Materials:

– Machined Components:

• 6061 Aluminum

– COTS Hardware:

• Plated Aluminum

• Stainless steels

• Plastics

➢ Manufacturing Process

– University of Illinois’ School of Chemical Sciences Machine Shop

– Milling and lathe capabilities

– 0.005” manufacturing tolerance



Aluminum Components

Tether Ring Ratcheting Case Ratcheting Cover

Handles

Pawl Shaft

Main Shaftand Receiver

Locking Levers - BlackNickel Plated Aluminum

McMaster PN: 1604A43


Anchor Shaft and Auger


Stainless Steel Components

302 Stainless SteelPawl Spring

McMaster PN: 9435K58

Ratchet Pawl – 300 SeriesMcMaster PN: 6283K32

Gear – 300 SeriesMcMaster PN: 6283K23

18-8 SS Receiver ScrewMcMaster PN: 92196A152

18-8 SS Pull PinMcMaster PN: 2362A21

Tether Ring – 300 SeriesMcMaster PN: 33815T51


18-8 SS Socket Screw – Spring LockMcMaster PN: 95198A660

18-8 SS Locking Lever LocknutMcMaster PN: 93625A250

18-8 SS Locking Lever ScrewMcMaster PN: 92125A244

18-8 SS Locking Lever WasherMcMaster PN: 92141A013

*Blue PN were incorporated in the CAD, but were not purchased from McMaster


Other Components

Auger Cover - Plastic Delrin® Acetal Plastic WasherMcMaster PN: 95647A163


• Lubricants: None• Adhesives: 30 minute Epoxy


Weight Breakdown


Weight Breakdown


Safety

Destiny Fawley



ALMA Safety

Loss of Small Parts

Sharp Edges

Unnecessary Rotation

Anchor Shaft Pinch Point

Handle Pinch Point

Entanglement of Tether

Auger Cover Pinch Point



ALMA Hazard Analysis



ALMA Hazard Analysis Continued



NBL Requirements

➢ The tool will be constructed using only NBL approved materials– The tool is designed to be made of the NBL approved metal aluminum 6061,

plastic, zinc coated steel, Delrin Acetal Plastic, and stainless steel.

➢ The mockup components shall not contain sharp edges and items capable of cutting or puncturing items coming into contact with them.– There will be a protective cover surrounding the auger in order to prevent the

diver's suit to be damaged by the sharp edges when transporting the auger to and from the testing environment.

➢ The tool should contain caution and warning tags for hazard areas, hardware identification, and addition of safety labels required by TRR.– The tool will contain the required labels as required by TRR.

➢ The hardware shall be designed to specify manufacturing to remove burrs, break all sharp edges and round all corners.– Machine shop has handled rounding all sharp surfaces other than the auger.

➢ Mockups and hardware shall be designed with drain holes or geometry to allow the free flow of air and water as required to support submersion.– The tool will not have any sealed sections that could retain air.

➢ The hardware should have mate/de-mate alignment marks.– These marks will be included on the tool before testing.



NBL Requirements Continued

➢ The hardware must withstand normal handling or kick loads and not present a safety hazard.– The tool will be machined of materials able to withstand normal handling

without breaking or causing a safety hazard. All connection points will be tightly secured to prevent disconnections that could cause a safety hazard.

➢ Avoid pinch points and/or sharp edges– The auger cover will protect against the only sharp edges (not rounded) on the

tool. The potential pinch points have been identified in the ALMA hazards section and have been remedied.

➢ All tools must have a tether loop which will allow the astronaut to use a tether with hooks to restrain the tool.– The tool will have a loop on the cover, the auger cover, and the auger shaft (each

of the separable components).

➢ All tools must be operable with EVA gloved hands.– The handles will be large enough to grasp with EVA gloved hands. The ratchet

will allow the astronaut to turn the handles without changing positions.

➢ Tool must not have holes or openings which would allow/cause entrapment of fingers.– The ratchet casing will prevent this hazard.



Requirement Compliance

Sara Legg




➢ The device shall remain anchored in the simulants without the use of an operator.

– Once the device is anchored into the test bed, the simulant mass acting on a large surface area auger will allow the tool to remain anchored without an operator.

➢ The device shall remain anchored in the simulants when pulled upward with a 15 lbf.

– Refer to testing and calculations slide

➢ Mass and volume of the device should be minimized.

– Balance between size/material and effectiveness/safety of tool

➢ The device can be operated manually or under power. Powered operations shall be driven pneumatically.

– The device is designed to be operated using manual force to deploy and store system and manual rotational force for anchoring.

➢ The device can have multiple parts that can attach and detach.

– The device has two different components that are attached through a pull pin.



Force Calculations



Testing Overview

➢ Team conducted 4 tests within a 32-gallon bin :

– Dry sand test

– Wet sand test

– Pebble mixed in wet sand test

– Gravel mixed in wet sand test

➢ Used a spring scale attached to the tether point on the anchor shaft of ALMA to determine maximum holding force.

➢ Equipment used: 6 bags of sand, 32 gallon bucket, 2 bags of gravel and 2 of pebbles




➢ The device (all parts, in stowed configuration) shall fit within a 10” x 10” x 18” volume.

– Refer to slide 9 for stowed dimensions.

➢ The device (all parts ) shall have a dry weight less than 20 lbs.

– Weighs 6.73 lbs. Refer to slide 24.

➢ The device shall be ambidextrous

– Both hands are necessary for the proper anchoring of the device.

➢ The device and any removable components shall have a tether attachment point 1” in diameter.

– There will be a 1” diameter loop on all three sections to attach a tether onto.

➢ The device shall be compatible with a chlorine water environment.

– None of the chosen materials will degrade in any way in a chlorine environment.



Structural Analysis - Ryan

➢Ensuring hinge durability➢Worst case: 50 lbs on handle ➢High loading on hinge pin

– 304 Hardened Stainless– 30-75,000 psi Yield Strength

26,500 psi



Operations Plan

Megan Geyer



Test Preparation Phase

1. Anchor in storage configuration should consist of the two handles parallel to the shaft with the locking levers pointing inwards towards the shaft.

2. With dominant hand, tether onto the silver, 1” key ring located on rotating anchor shaft.

3. Set the assembled tool in the testing bin with the bottom of the auger casing touching the testing material.

4. Hold the anchor shaft with your right hand with the locking levers facing self.

5. Grip the right locking lever with your left hand

6. Rotate the first locking lever counterclockwise until loose.

7. Keep left hand on the locking lever and move right hand from shaft to right handle.

8. Rotate the handle perpendicular to the shaft.

9. Rotate the locking lever one and one eighth turns clockwise until tight

10. Hold the anchor shaft with your left hand.



Test Preparation Phase Continued

11. Grip the left locking lever with your right hand

12. Rotate the second locking lever counterclockwise until loose.

13. Keep right hand on the locking lever and move left hand from shaft to left handle.

14. Rotate the handle perpendicular to the shaft.

15. Rotate the locking lever one and one eighth turns clockwise until tight.

16. Place non-dominant hand on the shaft and lift tool assembly from testing surface.

17. With dominant hand, tether onto the silver key ring located on the auger casing.

18. Release auger casing strap, grabbing from the side with greatest amount of slack.

19. Remove casing completely from assembly and release cover behind self.

20. Place ground engaging portion of auger into testing material with the shaft

normal to surface.

21. Move on to test execution phase.



Test Execution Phase

22. Complete Test Preparation Phase.

23. Assure that the ground engaging portion of the auger is on the testing material.

24. Grip shaft with both hands.

25. Apply downward pressure and rock the shaft in a circular, clockwise motion in

an effort to seat the ground engaging portion of the tool in the testing material for 5

seconds.

26. With one hand, rotate ratchet casing counterclockwise until locking levers face

self.

27. Place right hand on the right handle and left hand on the left handle.

28. Position hands as close to the ratchet as comfortable.

29. Maintaining position of self, apply downward and inward force and rotate tool

clockwise as far as comfortable.

30. Cease clockwise rotation and rotate counterclockwise as far as comfortable.



Test Execution Phase Continued

31. Repeat steps 8-9 until device is submerged to shaft tether point. With increased

resistance, hands may be positioned at different locations on the handle for

increased torque.

32. With one hand, tether onto the 1”, silver key ring on the ratchet casing’s top.

33. Rotate the ratchet casing counterclockwise such that handles are clear of the pull

plunger with the green loop.

34. Place one hand on the ratchet casing and another hand on the green loop.

35. Pull the green loop away from shaft and pull the ratchet casing up and clear of

tool.

36. Release the green loop and place the ratcheting section behind self.

37. Perform 15 lbf test on buried anchor.

38. Finish 15 lbf test on buried anchor.

39. Proceed to Test Closeout Phase.



Test Closeout Phase

40. Complete Test Execution Phase

41. Take ratchet with one hand and position above anchor shaft.

42. Note position of locking plunger and align with the position of locking hole on

anchor shaft.

43. Gently rotate ratchet casing clockwise/counterclockwise until plunger locks into

the shaft hole.

44. Place one hand on each handle, positioning hands as close to ratcheting case as

comfortable.

45. Rock the assembled tool in a circular, counterclockwise motion while applying

upwards force.

46. If no visible upwards motion of assembled tool, remove top 4 inches of sand.



Test Closeout Continued

47. Continue rocking the tool until it is unburied.

48. Remove tool from testing material.

49. Take auger casing from behind self.

50. Place auger casing on testing material and open with the opening facing up.

51. Place auger inside one auger casing half.

52. Rotate each locking lever so that each handle is parallel to the shaft.

53. Place tool in container to conclude test close out phase.



Thank You!

The Illinois Space Society’s ALMA team would like to thank the following people/organizations for all of their help and guidance for

this project.

➢ The University of Illinois Department of Aerospace Engineering

➢ Christopher Wynard, NASA Mentor

➢ Grace Gao, Ph.D., Faculty Advisor

➢ The Micro-g NExT staff

➢ The NBL staff

➢ NASA JSC

www.nasa.gov www.Illinois.edu


http://www.nasa.gov/

http://www.illinois.edu/


Conclusion

Questions?


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