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Ground-Based 1U Cubesat Robotic Assembly Demonstration

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Ground-Based 1U Cubesat Robotic Assembly Demonstration SSC20-WKI-05 Ground-Based 1U CubeSat Robotic Assembly Demonstration Ezinne Uzo-Okoro, Christian Haughwout, Emily Kiley, Mary Dahl, Kerri Cahoy Massachusetts Institute of Technology 77 Massachusetts Ave. Cambridge, MA 02139, USA (301) 370-6888 [email protected] ABSTRACT Key gaps limiting in-space assembly of small satellites are (1) the lack of standardization of electromechanical CubeSat components for compatibility with commercial robotic assembly hardware, and (2) testing and modifying commercial robotic assembly hardware suitable for small satellite assembly for space operation. Working toward gap (1), the lack of standardization of CubeSat components for compatibility with commercial robotic assembly hardware, we have developed a ground-based robotic assembly of a 1U CubeSat using modular components and Commercial-Off-The-Shelf (COTS) robot arms without humans-in-the-loop. Two 16 in x 7 in x 7 in dexterous robot arms, weighing 2 kg each, are shown to work together to grasp and assemble CubeSat components into a 1U CubeSat. Addressing gap (2) in this work, solutions for adapting power-efficient COTS robot arms to assemble highly-capable CubeSats are examined. Lessons learned on thermal and power considerations for overheated motors and positioning errors were also encountered and resolved. We find that COTS robot arms with sustained throughput and processing efficiency have the potential to be cost-effective for future space missions. The two robot arms assembled a 1U CubeSat prototype in less than eight minutes. INTRODUCTION (DARPA) Robotic Servicing of Today, as space becomes more accessible, Geosynchronous Satellites (RSGS) $400M there is a lack of affordable on-demand program aims to demonstrate that a robotic capability to address multiple government [1] servicing vehicle can perform safe, reliable, and commercial constellation needs for on- useful and efficient operations in or near the orbit servicing and assembly. The industry’s Geosynchronous Earth Orbit (GEO) first satellite life extension vehicle, Northrop environment. RSGS is using the custom- Grumman’s Mission Extension Vehicle-1 developed and large radiation-hardened Front- (MEV-1), completed its first docking to a client end Robotics Enabling Near-term satellite, Intelsat IS-901 on February 25, 2020. Demonstration (FREND) robot arm, which is a MEV-1 is designed to dock to geostationary 1.8 m arm from shoulder pitch to wrist pitch satellites whose fuel is nearly depleted and weighing 78 kg, with an additional 10 kg for does not make use of robot arms for its on-orbit electronics. servicing mission [2]. On-orbit robotic The need for low-cost, low-latency and agile assembly to date is costly, as evidenced by space infrastructure, which can reach strategic prior and current missions [3]. For example, the orbits such as GEO and Low Earth Orbit (LEO) Defense Advanced Research Projects Agency in addition to polar and International Space Ezinne Uzo-Okoro 1 34th Annual Small Satellite Conference Station (ISS) locations, could be realized using response time from a minimum of 30 days to a robotic assembly of modularized components less than 10 hours for a small satellite build and into CubeSats. A standardized modular deployment cycle. CubeSat and COTS-based robotic assembly This robotic-assembly based mission using could break the reliance on high-risk, high- propulsive “lockers” could help create a latency, high-cost legacy space hardware. resilient platform capable of rapidly Satellite cellularization [4][5][6][7] has made assembling and deploying scalable space incremental advances in the modularization of systems faster than NASA’s documented small satellite subsystems. However, this thesis minimum launch-on-demand response time (35 explores a new approach to CubeSat days) for the International Space Station (ISS) production based on the robotic assembly of crew rescue [8]. functional spacecraft components. There are four phases necessary to successfully Figure 1. Conceptual system design of the realize the mission concept. Phase 1 involves interior of the spacecraft locker. the ground-based robotic assembly of a CubeSat prototype using two dexterous arms We envision a new mission in which small and electromechanical components in a COTS robot arms are enclosed in free-flying laboratory environment and assessing different small spacecraft “lockers” of approximately 24 payload and propulsion options to optimize inches x 36 inches x 12.5 inches for the response time and sensing. This paper assembly of a new standard of small satellites. addresses the feasibility of Phase 1 and These mini-fridge-sized spacecraft “lockers” characterizes the systems engineering efforts with propulsion capability are intended to be required to develop in-space robotic assembly. orbit-agnostic in order to deploy on-demand Phase 2 involves the development and launch robot-assembled CubeSats where needed. The of a flight unit locker with robot arms and spacecraft locker houses two robotic arms, CubeSat modular components, including modular components including sensor and propulsion options for the CubeSats propulsion modules, and payloads for 1U to themselves and not just the spacecraft locker. 3U-sized CubeSats. The mission is expected to The spacecraft locker would be hosted at the deliver an unprecedented improvement in ISS Japanese Experiment Module Exposed Ezinne Uzo-Okoro 2 34th Annual Small Satellite Conference Facility (JEM-EF) [9][10][11], and house six Degrees of Freedom, and minimize on-orbit enough components to demonstrate the on- SmallSat assembly time by using the dexterous orbit assembly of five 1U CubeSats. The first robot arms while satisfying the given power prototype CubeSat would be a CubeSat consumption and weight requirements at a assembled on earth and deployed first in order given orbit. Thus, we employ multidisciplinary to test the deployment system. The four design optimization tools and methodologies remaining CubeSats - two with Radio Science focusing on the second key gap: testing and Experiments (RSE) and magnetometers, two modifying commercial robotic assembly with visible (VIS) sensors - will be robotically hardware suitable for small satellite assembly assembled on-orbit. The ISS Phase 2 in space. Given that the search parameters in technology demonstration is expected to prove the Inverse Kinematics task for a robot with the on-orbit assembly of modular many degrees of freedom are constant, the reconfigurable CubeSats, increase Technology Genetic Algorithm approach in combination Readiness Level (TRL), and assess response with the robot simulation is used. We also time quantitatively. describe the technology choices and redundancy levels of the different subsystems Organization in this optimal on-orbit assembly design. Following a state-of-the-art review of current robot arms in space, a feasibility study on the COTS Robot Arm Flight Heritage use of dexterous COTS robot arms in space is To date, most on-orbit assembly missions are analyzed. We summarize the study results not for small satellite on-orbit assembly, but toward feasible on-orbit CubeSat robotic instead are designed to support ISS assembly. experiments, exploration, and servicing (refuel Next we describe the lab prototype or repair existing satellites) missions demonstration of the robotic assembly of a 1U [15][16][17][18]. Previous missions include CubeSat by two dexterous COTS robot arms. the U.S. Defense Advanced Research Projects The assembly process uses two COTS robot Agency’s (DARPA) Orbital Express program arms to assemble modularized boards fastened [19], the DARPA Phoenix Program [20], and with magnets into a small satellite. The the Jet Propulsion Laboratory’s (JPL) Mars assembly steps use open-loop control and a Insight mission [21]. Robotic manipulators, Python software program. We show that the important for scientific experiments and the robotic arm assembly of modularized construction and maintenance of the ISS, have components is a viable option for a new class conducted on-orbit robotic assembly. of CubeSats. Examples include the Shuttle Remote Lastly, we provide a summary of the work and Manipulator System (SRMS) [22], also known introduce the next steps for space qualification as Canadarm, which is a 16.9-meter, seven of the system. degree of freedom (DOF) manipulator with a relocatable base; the National Space FEASIBILITY OF ROBOT ARMS IN Development Agency of Japan’s (NASDA) SPACE Japanese Experiment Module (JEM) Remote We review the current state-of-the-art of robot Manipulator System (JEMRMS), which is a arms in space. We assess the feasibility of the 9.91-meter, six DOF manipulator; and lastly, on-orbit assembly of small satellites using the European Robotic Arm (ERA), which is an Commercial-Off-The-Shelf (COTS) hardware 11-meter, seven DOF manipulator [23]. without humans-in-the-loop. We select low- cost robot arms, LewanSoul xArm Robots with Ezinne Uzo-Okoro 3 34th Annual Small Satellite Conference Table 1. Shows the gaps in select current on- servicing. The National Aeronautics and Space orbit assembly/servicing space missions Administration (NASA) Goddard Space Flight Center’s (GSFC) RESTORE-L servicing These manipulators employed very large mission [30], is also a robotic spacecraft robotic arms to deploy, maneuver, and capture equipped with the tools to rendezvous with, payloads. Hirzinger’s patent on a multisensory grasp, refuel, and relocate satellites to extend robot was tested aboard the Columbia shuttle, their lifespan. Lastly, NASA’s Dragonfly has which
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