Magnetic Gear and Sensor Technology to Enable Survival and Robotic Actuator Dexterous Operation through the Lunar Night

This proposal addresses a critical need for space actuators in NASA’s exploration missions and the commercial space sector, particularly for environments like the lunar surface. Our magnetically geared actuator is designed to meet high torque requirements while overcoming the limitations of traditional motor-gear systems, such as backlash, friction, wear, and shock vulnerability. These issues affect current robotic manipulators like SSRMS (Canadarm2) and JEM-RMS (Kibo), as well as actuators used in missions like Curiosity and Mars 2020, which are inadequate for lunar mission demands. The magnetic gear actuator offers a lightweight, low-power, and compact solution that can endure the extreme environments of lunar missions, including surviving the lunar night. Integrated into an MIT-cheetah style dexterous end effector, it could enable fine manipulation tasks, such as mating/demating connectors and handling tools, which are essential for Artemis lunar surface operations. Phase II funding will be used to integrate the magnetic gear with impedance controller from Phase I into a robotic end-effector for a near-term Generic Robotic Torquer tool, supporting the design, testing, and TRL 5 demonstration of this actuator developed with partners Rob Ambrose & Gray Thomas at TEES, and Josh Figuered at Novium Intuitive Machines provided a Letter of Capital Commitment for our compact and heat-efficient solution which eliminates the need for traditional clutches & temperature-sensitive torque transducers. With current customer MDA Space providing a Letter of Capital Commitment, we aim to win Lunar Outpost also. capabilities for lunar missions and other space applications. The target market includes the rotary electromechanical robotic arms and manipulators in the global space sensor and actuator market, particularly for rovers and landers. Thereafter, the allied nation “smart actuators” market and dexterous end effector for intrinsically safe cobot market shall be penetrated.
Benefits: Our magnetic gear actuator technology directly supports NASA’s mission directives by enabling advanced robotic manipulation for sustainable lunar exploration and beyond. As part of NASA's Moon-to-Mars objectives, the actuator is well-suited for tasks in extreme environments, such as permanently shadowed lunar regions and lunar surface infrastructure deployment. The inherently series elastic actuator technology configured as a MIT cheetah-style end effector enhances dexterity, robustness, and versatility in tasks typically requiring human hands, such as assembly, maintenance, sample collection, and tool manipulation. For lunar missions, a dexterous end-effector with magnetically geared actuators could assist in operations like mating/demating power/data connectors, opening/closing panels, handling cables, and managing payloads, critical for infrastructure outfitting. It could be also ideal for tasks such as moving cryogenic samples, small tool use, and interacting with non-cooperative interfaces, vital for science utilization and in-space servicing. Additionally, the actuator's low size and mass, combined with high torque capability, make it an ideal solution for fine manipulation tasks in both lunar and in-space environments. Incorporating FluxSense™ technology into this actuator, it replaces traditional mechanical components, enabling more efficient, compact, and durable systems. Specifically in Phase II, the technology will be derisked for Intuitive Machines, aligning with NASA's goals for autonomous operations during uncrewed periods, ensuring mission continuity in challenging environments, by supporting a Generic Robotic Torquer end-effectors that could also be applies as a survive the night lunar tools with an operation principle similar the Pistol-Grip Torque Measuring Power Tool (PGT). MDA Space is interested in similar usage of the technology to support Lunar Outpost. The robotic thermal management benefit ameliorates Civil Space Shortfall #1, #5, & #31. Magnetic gear with FluxSense™ technology offers significant commercialization opportunities across a wide range of industries, particularly in the growing robotics and automation sectors. By incorporating IoT connectivity, the technology can be integrated into the future of Industry 4.0, offering advanced capabilities in cobot applications and robotics automation systems. The "Smart Actuator" enables robust, dexterous manipulation in harsh and delicate environments, offering potential for commercialization in both terrestrial and space sectors. With the integration of IoT connectivity and the ability to scale for diverse industrial needs, the technology will expand into markets such as process automation, automotive, electronics, healthcare, and beyond, servicing both high-end robotic actuators and general-purpose automation systems. In industrial applications, this technology can address key challenges such as low-maintenance, high up-time tasks in turbines, pumps, and industrial positioning systems. It is ideal for high-power, high-impact activities like catching and impact absorption, as well as delicate tasks such as mirror wiping, wire detangling, and circuit board maintenance. The actuator’s adaptability to super-low temperatures makes it an excellent fit for deep space or planetary exploration, and its backdrivable interaction supports collaborative human-robot operations, essential for applications like augmentation arms or exoskeletons. The gear's strength and performance also make it valuable in high-impact work environments such as jackhammer positioning or part-holders for hammering operations, providing safety and precision. The gear can operate in extreme environments for electronics and in-space manufacturing or clean pharmaceutical manufacturing. During Phase I, the innovation has already demonstrated success in commercial markets, with modified variants of the magnetic gear sold to Blue Bell Creameries for ice cream processing and to MDA Space.