Robonaut Setup and Taskboard Training 5/2/2013 Curtis Kershner/ ER Dennis Bentson/ ER Leah Pike/ ER Instructors

Page No. 2 ISS_CM_019 (Rev 08/2009) Lesson Objectives  Robonaut overview  Hardware overview  Robonaut safety and hazard controls  End Effector safety and motion stop  Cabling overview and charging sequence  Taskboard overview

Page No. 3 ISS_CM_019 (Rev 08/2009) Robonaut Overview  Three phase project  Phase I – Stationary with Torso attached to a stanchion  Phase II – IVA Mobility Unit: Two 7-DOF legs attached to Phase I Torso  Phase III – EVA Mobility Unit: EVA Torso attached to Phase II Legs  Phase I – Torso Only  Launched on STS-133 in February 2011  Required crew assembly and stowage  Performed initial proof of concept operations  Taskboard operations  First tool use and simulated IVA activities  Tele-operation

Page No. 4 ISS_CM_019 (Rev 08/2009) IVA Mobility Unit  IVA Mobility Unit  Manifested on SpaceX-3 with a launch date of November 11, 2013  Consists of Robonaut Legs, Battery Backpack and Phase I Torso upgrades  To be assembled by the Inc 37/38 crew (Hopkins/Mastracchio)  Assembly and Checkout  Legs and Battery Backpack will be attached to the current torso  Phase I Torso will be upgraded with a suite of new processors to provide increased computing power required for the addition of the legs  Checkout planned for Inc 37/38  Will verify all hardware functioning appropriately  Verify all safeties are operational  Initial joint movements and end effector checkout

Page No. 5 ISS_CM_019 (Rev 08/2009) Hardware Overview  Current Torso:  42 Degrees of Freedom (DOF):  Two 7 DOF Arms  Two 12 DOF Hands  3 DOF Neck  1 DOF Waist  7 Degree-of-Freedom Legs joined to the current Torso  Two Multi-purpose End Effectors (EE) that interface with IVA handrails and seat tracks  Battery Backpack with Lithium Ion batteries provide up to 8 hrs of operation  Wireless communication hardware integrated with Backpack

Page No. 6 ISS_CM_019 (Rev 08/2009) Safety Overview  Robonaut is designed to interact and work side by side with people and Astronauts  No Operational keep out zone  Will pause motion if an obstruction is encountered  Safeties at both the joint level and robot level  Joints level jerk faults  Robot level force sensors (6 total – 4 in torso, two in the legs)  When faulted, the upper body joints will engage the brakes for 1 second and then release so the upper body is compliant  Prevents entrapment and ability to easily maneuver joints  Torso must be powered, otherwise the brakes will engage and the joints can not be backdriven  The Legs do NOT have brakes and are compliant even without power

Page No. 7 ISS_CM_019 (Rev 08/2009) Robonaut Safety  Handling Robonaut  Keep hands away from ignition sources, Koozies on when not in use  Do not route power cable such that is it is in the way of Robonaut’s joints while charging  Remove power to the UOP inhibit prior to mating or demating the Robonaut power cable. Backpack handle

Page No. 8 ISS_CM_019 (Rev 08/2009) Hazard Controls Crew members will observe a “no touch” zone around the back of the neck and elbow and leg joint flexion while Robonaut is powered. Do not handle Robonaut by its neck, head, wrists or fingers unless specifically called out in procedures.

Page No. 9 ISS_CM_019 (Rev 08/2009) End Effector Safety Overview  Interfaces with ISS handrails and ISS seat tracks to “climb”  Jaws can manually be opened by pressing two buttons and pulling the mechanical release bar down or up  At any point, the EE can be released by the crew and the Robot can be pushed out of the way  In case of an emergency, this action can be accomplished within 2 minutes to clear a hatch in case a rapid egress is required F F DUAL HANDLE RELEASE BUTTONS (UNLOCKED)

Page No. 10 ISS_CM_019 (Rev 08/2009) Motion Stop Controller  Nominal IVA operations will not require the motion stop to be connected  A jumper will be installed to remove the need for the Motion Stop health monitoring after the IVA mobility upgrade has been checked out  Depressing the yellow button removes Motor Power & temporarily engages the brakes on the Torso joints  Brakes will release after one second and the torso joints will then be compliant  The Legs do NOT have brakes and can be maneuvered at any time  Green button used to clear software faults

Page No. 11 ISS_CM_019 (Rev 08/2009) Robonaut Stowage (LAB1P1)

Page No. 12 ISS_CM_019 (Rev 08/2009) Robonaut Cabling Overview  IVA Mobile Robonaut will communicate wirelessly with an ISS wireless network  Will still be able to plug directly into the JSL network via Ethernet connection  A power cable will be connected from an ISS UOP to charge the backpack while not in use.

Page No. 13 ISS_CM_019 (Rev 08/2009) Charging Sequence  Connect for Charging  Disable power at UOP  Connect power cable at UOP and connector located on the bottom right of the backpack  Route cable such that it is not in the path of the Robonaut joints  Enable power at UOP  Disconnect after Charging  Disable power at UOP  Disconnect power cable from UOP and Robonaut backpack  Press Power Switch located on the bottom left of the backpack to power on Robonaut

Page No. 14 ISS_CM_019 (Rev 08/2009) Robonaut Visual Indications Motor Power indicator lights on head and chest Logic Power indicator lights on hands

Page No. 15 ISS_CM_019 (Rev 08/2009) Robonaut Taskboard Panel A - Powered Panel Assy 1.Non-locking 2-way switch with switch guard 2.Push button switch array (blue and green) 3.Locking 3-way switch 4.Locking 2-way switch 5.2-way rocker switch with finger guards Panel B - IVA Panel Assy 6.Fluid Quick Disconnect (QD) Valve Used for fluid connections on station 7.Toggle Valve 8.Metering Valve 9.Circular connector Used for powered connections on station 10.Ball Valve 11.Needle Valve Panel C - EVA Panel Assy 12.Microconical Fitting Interfaces with the Round Scoop EVA handling tool 13.Tether Ring Assembly 14.EVA Handrail Assembly 15.7/16” EVA Bolt 16.EVA Change-Out Mechanism (ECOM) Socket Interfaces with the Body Restraint Tether (BRT) and Multi-Use Tether (MUT) Panel D - Stowage Panel Assy 17.Tether loops (x4) 18.Strap Assembly

Page No. 16 ISS_CM_019 (Rev 08/2009) Robonaut Taskboard Installation  Taskboard is installed to ISS seat track by tightening thumb screws located in the four corners of the taskboard. Lever on side of taskboard is moved to “lock” which pulls the frame down onto the standoff.  Minimum of two taskboard thumb screws are required to be hand tightened. Location must be one on each side and diagonal.  Task panels are slid into place per execution note and locked down by turning four captive quarter-turn fasteners.  Minimum of two task panel quarter-turn fasteners are required to be engaged. Location must be one on each side and diagonal.  Task panel A receives power via USB cable and laptop

Page No. 17 ISS_CM_019 (Rev 08/2009) Take Homes  Handling and safety constraints  End Effectors can be released by crew at any point  Motion stop will be used during checkout operations  Disable power at the UOP before mating/demating power cable  Route power cable such that it is not in the path of the Robonaut joints  Motor power indicators on torso and backpack mean robot is able to move, logic power on hands indicate electronics are powered, and backpack has robot powered indicator  A minimum of two fasteners are required to be engaged for taskboard and task panels located diagonally from each other