A mobile work station concept for mechanically aided astronaut assembly of large space trusses

This report presents results of a series of truss assembly tests conducted to evaluate a mobile work station concept intended to mechanically assist astronaut manual assembly of erectable space trusses. The tests involved assembly of a tetrahedral truss beam by a pair of test subjects with and without pressure (space) suits, both in Earth gravity and in simulated zero gravity (neutral buoyancy in water). The beam was assembled from 38 identical graphite-epoxy nestable struts, 5.4 m in length with aluminum quick-attachment structural joints. Struts and joints were designed to closely simulate flight hardware. The assembled beam was approximately 16.5 m long and 4.5 m on each of the four sides of its diamond-shaped cross section. The results show that average in-space assembly rates of approximately 38 seconds per strut can be expected for struts of comparable size. This result is virtually independent of the overall size of the structure being assembled. The mobile work station concept would improve astronaut efficiency for on-orbit manual assembly of truss structures, and also this assembly-line method is highly competitive with other construction methods being considered for large space structures.