Canadarm and Canadarm2SSP / ISS Partnerships

Lessons Learned

William MackeyCounsellor Space Affairs - Canadian Space Agency

Canadian EmbassyWashington DC

NASA PM Challenge 2012Orlando, Florida

February 23, 2012

IntroductionOutline

• Canadarm Program and System Overview• ISS Partnership Structure• Mobile Servicing System Overview• Canadarm – Canadarm2 Comparison• ISS Lessons Learned

• Expect Change• Expect System Failures• Expect the Unexpected

• Future Exploration Programs

Canadarm Program OverviewHistory•1969 - NASA invited Canada to participate in the US space shuttle program. •1975 - MOU between the Canadian government and NASA was signed for

• $110 million program for the first Shuttle Remote Manipulator System (SRMS), later to be named ‘Canadarm’ and a ground-based simulation facility (SIMFAC). Prime Contractor: Spar Aerospace Ltd.

•1981 - This first Canadarm was a donation to US space shuttle program from Canada.

Missions:•STS-02 in November, 1981 - First shuttle flight with the SRMS.•STS-03, STS-04, STS-07 and STS-08 were the official Orbiter Test Flights (OTFs) that demonstrated that the SRMS met all its performance requirements.•Follow-on build program for four additional arms (arms 202, 301, 302, and 303) were delivered under a direct NASA contract to Spar for next 3 arms worth $68M.•SRMS was involved in 91 Shuttle missions, handling over 72 payloads & 75% of EVAs.•Arm 302 was lost in the Challenger accident that occurred in January, 1986.•Orbiter Boom Sensor System (OBSS) was later developed for tile and RCC inspection after the Columbia accident. Now an Integrated Boom Assembly (IBA) on ISS.

Canadarm System Overview

Space Vision System (SVS)

ISS Partnership Structure History•1989 - NASA invited Canada to participate in the Space Station Freedom program.

• IGA Art. 1: "…, under the lead role of the United States for overall management and coordination …"

IGAIntergovernmental Agreement:• Legal Regime• Top-Level Political Commitments• Multilateral (15 nations)

NASA/CSA NASA/ESA NASA/GOJ NASA/FSA

Memoranda of Understanding:• Detailed Implementation• Roles & Responsibilities • Obligations & Rights

U.S.- Canada Government Framework Agreement and Implementing Arrangements

Mobile Servicing System (MSS)HistoryThe Mobile Servicing System comprises: •Canadarm2 - Space Station Remote Manipulator System (SSRMS) : 17-meter long arm with seven joints capable of relocating and handling large payloads, including a loaded 116,000-kg (256,000 lb) Orbiter.

•Dextre - Special Purpose Dexterous Manipulator (SPDM): two armed robot capable of handling many maintenance tasks currently performed by EVA astronauts.

•Mobile Base System (MBS): a work platform and storage area for SSRMS, SPDM, various tools and payloads.

•Robotic Workstation: an internal command & control station used by astronauts (the RWS is an MSS system that is being supplied under separate contract to NASA).

•Artificial Vision Unit (AVU): an image processing system to be used for payload positioning.

MSS System Overview

Remote Multi-Purpose Support Room at CSA

NASA Flight Control Room

Canadarm Canadarm2

Location Installed on each shuttle and returns to Earth.

Only one installed on the International Space Station and stays permanently in space.

Performance Requirement

65,000 lb payload later enhanced to 256,000 lb for berthing to ISS

256,000 lbs for loaded Orbiter capture and berthing to ISS

Length 15 metres (52.0 feet) 17.6 metres (57.7 feet)

Weight 410 kg 1,641 kg

Diameter 33 cm (Ext. Diameter of Composite Boom) 35 cm (Ext. Diameter of Composite Boom)

Speed of Operations

Unloaded: 60 cm/sec Loaded: 6 cm/sec

Unloaded: 37 cm/sec Loaded: Station assembly 2 cm/sec.; EVA support:15 cm/sec.; Orbiter: 1.2 cm/sec

Range of Motion Reach limited to length of arm.

Moves end-over-end to reach many parts of International Space Station limited only by number of Power Date Grapple Fixtures on the Station (PDGF). PDGFs located around the Station provide power, data and video to the arm through its Latching End Effectors (LEE). The arm can also travel the entire length of the Space Station on the Mobile Base System.

Canadarm vs Canadarm2

Canadarm vs Canadarm2 Canadarm Canadarm2

Base Fixed to the shuttle by one end. No fixed end. Equipped with LEEs at each end.

Degrees of freedom

6 degrees of freedom. Similar to a human arm: shoulder (2 joints), elbow (1 joint), and wrist (3 joints).

7 degrees of freedom. Much like a human arm: shoulder (3 joints), elbow (1 joint), wrist (3 joints). However Canadarm2 can change configuration without moving its hands.

Joint rotation Limited elbow rotation (to 160 degrees).

Full joint rotation. Joints (7) rotate 540 degrees. Larger range of motion than a human arm.

Senses No sense of touch

Force-Moment Sensors provide a sense of “touch.” Automatic vision feature for capturing free-flying payloads.Automatic collision avoidance.

Composition 16 plies of high modulus carbon fibre-epoxy 19 plies of high strength carbon fiber–thermoplastic

Repairs Repaired on Earth. Designed to be repaired in space with ORUs (Orbital Replacement Units). Built-in redundancy.

Control Autonomous operation or astronaut control Autonomous operation or astronaut control

Cameras 2 (one on the elbow and one on the wrist)

4 colour cameras (one at each side of the elbow the other two on the LEEs)

30 ISS Elements

ISS Assembly – Canadarm/Canadarm2 43 ISS Elements / 381,290 kg

ISS Assembly – Canadarm/Canadarm2 43 ISS Elements / 381,290 kg

27 ISS Elements

13 Handoffs

ISS Element Mass (kg)88 FGB 1934088 Unity Node 1155592 Z1 Truss 835792 PMA 3 115697 P6 Truss 1579098 US Lab 15184102 MPLM - Leonardo 11341100 SSRMS/SLP 3059100 MPLM - Raphaello 8509105 EAS 640105 MPLM - Leonardo 9450108 MPLM 9173111 MPLM 10543113 P1 12477115 P3/P4 Truss 15824116 P5 Truss 1864117 S3/S4 Truss 16184118 S5 1814118 ESP-3 2575123 JEM ELM-PS 8388119 S6 14113127 ELM-ES 1200127 JEM-EF 3778127 ICC-VLD 4100129 ELC1 6366129 ELC2 6357132 MRM1 8000

Total: 227,136

CanadarmSTS

ISS Element Mass (kg)Airlock 6032 104S0 12146 110MBS 1443 111S1 12747 112P1 12477 113MPLM 8194 114MPLM 9507 121P3/P4 Truss 15824 115P5 Truss 1864 116S3/S4 Truss 16184 117S5 1814 118ESP-3 2575 118Node 2 (Harmony) 14322 120P6 Relocate 15790 120Columbus 12078 122SPDM 1556 123JEM PM - Kibo 14772 124MPLM - Leonardo 12705 126S6 14113 119ELM-ES 1200 127JEM-EF 3778 127ICC-VLD 4100 127MPLM 12478 128ELC1 6366 129ELC2 6357 129Node 3 18144 130Cupola 1880 130

MPLM - Leonardo 12371 131ICC-VLD 3778 132MRM1 8000 132

Total: 264,595

STSCanadarm 2

Expect ChangeCanadarm: Payload Deployment & Retrieval (PDRS) to ISS Assembly

Over 90% of the electronics was redesigned to improve safety, reliability and functionality during 29 year program.•New Joint control servo electronics•End Effector•Numerous add-ons: Foot Restraints, Materials science,

brackets/ connectors for additional cameras etc...•Control software - 30 new releases

Canadarm 2 •SSF to ISS: Partners, Program Structure – USOS & RSOS,

PMO infrastructure, interfaces (DMS -MPAC to CCS) •End-to-End System Architectures – NASA responsible for RWS•Deletion of MSS MMD and Voice Activation•Utilization of the Artificial Vision system•Assembly Sequence – affecting ops products•Software enhancements due to requirement changes and failures. e.g. Hot Backup•Shuttle Retirement - Launch & Return to Launch & Burn

Expect System FailuresCanadarm: The SRMS experienced only three on-orbit failures during its operational life:

• Wrist Yaw (WY) Commutator Scanner Assembly (CSA) failure during STS-41B, • Loss of power to the Elbow Pitch (EP) SPA during STS-51I, and • SPEE power connection failure during STS-57. FDIR: Prime, Backup &Direct Drive – multiple modes impacted by single failure

Canadarm 2 • Operational certification on-orbit starting on assembly flight• Several minor anomalies (eg: 1553 chip set, RDC BIT, Camera functions, Polarity) • One ‘infant mortality’ failure – SSRMS Wrist Role Joint failure required R&R • Assembly missions continued using redundant string and NEW C&C Feature,

Degraded Joint Operations (DJOPs)• WR Joint returned for failure analysis, refurbishment and recertificationFDIR: Independent Prime & Redundant Strings, Design for Minimum Risk• Scared for Backup Drive – Implemented Hot Backup software for Free FlyersLessons include: • Redundancy, Reliability & Flexibility (Cross-strapping & software enhancements) • Attention to Details - Units of measurement, Coordinate frames,

Polarity, Interface Standards, Fit Checks, Workmanship Inspections.

Expect the UnexpectedCanadarm: Operational & Performance Requirements never accounted for:

• Knocking Ice off the waste water vent nozzle

STS-41G SRMS used to Push on SIR-B Antenna to Latch it Down

STS-51D- SRMS/“Fly-swatter” used to Snag Separation Switch on Syncom-3

Berthing Zaria to Unity

Payload Hand-offs to Canadarm2

Inspection of RCC and TPS Tiles with OBSS

HST Repair

Expect the UnexpectedCanadarm 2: Operational & Performance Requirements never accounted for: • Ground Control (Canadarm2 & Dextre) – Auto vs Manual Control • Degraded Joint Operations (DJOPs)• Hot Backup for Free Flyer Capture• EDF removal for Deployment – EVA crowbar required• Operate from a Russian Segment Base Location• Robotics On-Orbit Servicing Demonstrations (RRM)

Solar Array Repair with OBSS (IBA)

Assembly with DJOPs back-up control mode

Hot Backup for HTV Capture

Expect IPs on Exploration ProgramsSpace Shuttle Program: •Canadian SRMS contribution in return for NASA contracts to Canadian Industry.

• Customer-Contractor based relations were beneficial to both nations.

International Space Station Program:• GoC partnership with USG – secures political support • MSS Integral to USOS under NASA leadership• Shared responsibilities for MSS – provided oversight and risk management• Software Interface/Partitioning/Functional Allocation complications drove costs• International Travel and Astronaut Training costs elevated

Future Exploration Programs:• International partnerships are costly but inevitable • Agreements to be based on national policies, finances and trust• Agreements for critical systems on critical paths to be mutually beneficial and binding• Agreements for end-to-end systems/element barters work – avoid exchange of funds• Avoid Customer-Contractor type International Partnerships – embrace mutual trust• Expect political pressures, ITAR, compromise, shared risks, change, system failures

and the unexpected