End-effector for robotic assembly of welded truss structures in space

In June 1987, work was initiated at LaRC on end-effectors and preloaded joints for robotic truss assembly. This is part of an on-going research effort centered on a test facility that assembles 1 inch x 2 m identical struts into an 8 m diameter x 1.5 m deep platform truss. A detailed description of the test facility was published. The end-effector being used for the LaRC assembly demonstration is quite suitable for the Precision Segmented Reflector or other precision applications. These require high stiffness provided by mechanical joint preloads. Stiffness obtained in this manner is only required and provided over a load range far less than the ultimate strength of the strut tubes. Beyond this useful range, truss behavior is somewhat unpredictable. Mechanically preloaded joints of this type are less suitable for applications such as the Aero Brake where predictable strength and stiffness are required over a greater fraction of the load bearing capacity of component parts. Preliminary studies of the Aerobrake support truss indicate that struts of at least 3 different diameters and various lengths would improve performance. The double-ended end-effector currently in service is designed for only one diameter and length. Anticipated single-ended versions can accommodate varying lengths but not multiple diameters. Tradeoff considerations for welded joints relative to their mechanically preloaded counterparts are presented. Conclusions from this research are as follows: (1) repair by cut and re-weld on the original weld site should be research; (2) welded joints, though repairable, should not be used where high repair frequencies are anticipated; and (3) welded joints should be considered for an Aero Brake truss.