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NEW APPROACH on ROBOTIC ARM DESIGN: FULLY MODULAR ARM ARCHI- TECTURE UTILIZING NOVEL SPACE INTERFACE Virtual Conference 19–23 October 2020 M

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NEW APPROACH on ROBOTIC ARM DESIGN: FULLY MODULAR ARM ARCHI- TECTURE UTILIZING NOVEL SPACE INTERFACE Virtual Conference 19–23 October 2020 M i-SAIRAS2020-Papers (2020) 5059.pdf NEW APPROACH ON ROBOTIC ARM DESIGN: FULLY MODULAR ARM ARCHI- TECTURE UTILIZING NOVEL SPACE INTERFACE Virtual Conference 19–23 October 2020 M. Kortmann1, C. Zeis1, C. A. de Alba-Padilla2, B. Grzesik2, K.-U. Schroeder1 and E. Stoll2 1Institute of Structural Mechanics and Lightweight Design, RWTH Aachen University, Wuellnerstraße 7, 52062 Aa- chen, Germany, E-mail: [email protected] 2 Institute of Space Systems, TU Braunschweig, Hermann-Blenk-Str. 23 38108 Braunschweig, Germany, E-mail: [email protected] ABSTRACT weight-optimized development, design and sizing. Be- sides the full-size demonstrator based on the iBOSS Robotic systems become more and more important concept and the iSSI, a smaller version is also pre- for space applications due to the flexibility in tasks sented, which is dedicated for the use in more compact they can perform such as docking assistance, support- applications such as cube-sats and rovers. Here, an ad- ing extra-vehicular activities (EVA), as well as ditional challenge needs to be faced as the intended maintenance tasks. For these purposes multiple differ- functionalities need to be integrated in even less build- ent robotic arms have been developed, especially for ing volume. missions which are intended to demonstrate on-orbit Finally, the first test results of the four degree-of- servicing (OOS) and assembly (OOA) capabilities. freedom, full size demonstrator will be presented. The current paradigm is the design of specialized ro- The paper will present the concept of a novel modu- botic manipulators to meet the requirements for a spe- larized robotic arm and its mechanical and weight-op- cific mission profile. timized development, design and sizing. It features This research aims to develop a modular robotic modules containing one joint and two multi-functional arm for multi-purpose and multi-mission use that can interfaces, which allows for OOS and OOA. be individually configured for the mission at hand. The underlying concept for the robotic part of the 1 INTRODUCTION system is a rotational joint which rotates under an an- At present, robotic applications play a major role gle of 45 degrees to the normal axis. This eliminates in unmanned exploration with rover systems. Further- the need for different types of joints, reduces the com- more, they are routinely used for berthing, cargo plexity of the modular system and the system requires transport or EVAs on the ISS and are therefore indis- less stowage space compared to a traditional universal pensable for manned space flight. In the future, how- joint set-up. The modular design offers further ad- ever, robotic applications will assume an even more vantages such as a flexible assembly and reconfigura- fundamental position in space activities [1-7]. tion in orbit, re-use of modules and the possibility to Due to the increase in satellites operated in orbit utilize different end-effectors and tools. Each module new concepts and solutions are needed to guarantee is based on the iBOSS (intelligent Building Blocks for safe and sustainable access to space. One enabling On-orbit Satellite Servicing and Assembly) concept technology in this regard is robotic on-orbit servicing, and consists of one rotational actuator with a tubular which includes e.g. repair, maintenance and disposal structural section attached to both sides. Each end of a of satellites. In addition, the assembly of large struc- structural section contains an iSSI (intelligent Space tures and additive manufacturing ("3D printing") in or- System Interface), giving each module two multi- bit are interesting concepts, as such technologies allow functional interfaces. The interface includes a mechan- the development of new classes of spacecraft using au- ical connection, power and data transfer and the means tonomous robots. for heat exchange between modules. The modules can However, currently robotic arms for use in space be connected using the iSSI and thus forming the ro- are mainly designed only for one mission and thus for botic arm system. With each added module the overall one specific purpose or application. This usually re- system gains one degree-of-freedom. The iSSI can not sults in high effort and costs making robotic arms un- only be used to interconnect the modules but also for attractive for a large number of missions. To overcome mounting the robotic arm to the spacecraft or to attach these challenges a new approach using a modular ar- different types of end-effectors or sensors. chitecture in combination with a different kinematic This paper will outline the concept of the modular- compared to the current state-of-the-art is presented in ization of the robotic arm and its mechanical and i-SAIRAS2020-Papers (2020) 5059.pdf this paper. Using a modular approach makes the ro- At the end of every tubular section one iSSI is inte- botic system highly flexible to comply with different grated making it possible to connect the modules with types of missions and requirements, such as degrees of each other, to the spacecraft or to different tools and freedom or arm length, without the need to change the end-effectors. Also, every module houses the relevant design. Furthermore, the system can even be modified electronics to drive the motors and communicate with during the mission. The alternative structure, which adjacent modules and the host spacecraft’s avionics. utilizes a joint rotating under a 45° to the normal axis, increases the redundancy of the system and makes it possible to get to hard to reach places. 2 MODULARIZATION APPROACH The modularization approach is based on the iBOSS Project (intelligent Building Blocks for On-or- bit Satellite Servicing and Assembly) which adapted a Figure 2: Conceptual setup of a robotic arm module modularization on component level, meaning one 3 ROBOTIC BASICS module would house, for example a reaction wheel, a propulsion unit or an antenna with the necessary elec- Robotic systems can be seen as combination of a tronics. Combining modules with all necessary com- mechanical system with a control system, comprised ponents and subsystems would result in the final, of actuators and sensors [9]. From this type of system working satellite. To enable the connection between the sub-group called robot manipulators is derived, the modules, the iSSI (intelligent Space System Inter- which is the most applied among the whole group. The face) has been developed which will also serve as con- robots in this subgroup can be defined as systems com- necting element for this robotic arm concept. This in- posed by links, joints and end-effectors [10]. The de- terface is capable of initiating a mechanical connection velopment of a modular manipulator combines all and transfer power, data and thermal energy. [8] these techniques with a modular structure. 3.1 Reconfigurable or Modular Robots Reconfigurable robots have been approached in different cases and interesting devices have been pro- posed. The work of Fukuda and Nakagawa, who de- veloped a system of individual cells, which could work together in applications such as maintenance in a stor- age tank, is one example [11]. There are other notable works of reconfigurable robots using modules that can be combined in different ways for configuring com- plex robots [12-14]. Other, newer approaches focus in the locomotion [15-16] and space applications [17- 18]. In every case the modules can be combined from one degree of freedom (DOF) up to n-DOF, the limit being the number of available devices. The implemen- tation of parallel joints makes a robot become redun- Figure 1: The iSSI in its current version with integrated fea- dant [19]. tures for power and data transfer 3.2 Redundant Robots Transferring this concept to the robotic arm system the These kind of robots have benefits as well as chal- joint assembly is the relevant component which in this case is the same for every module. Figure 2 shows a lenges. One benefit is the possibility to reach a posi- simplified view of the basic setup for the robotic mod- tion with any orientation [20]. For a high degree of re- ule. The motor and gearbox with an integrated bearing dundancy, a non-stop functionality can be applied, i.e. are the key mechanical elements of the joint and ena- if a motor breaks down, the loss can be compensated ble the rotational movement of the arm. On both sides using the rest of the functional motors, keeping the of the joints two tubular cross-sections are fitted which tasks achievable. Moreover, a redundant robot can be represent the structure of each module. seen as a non-redundant robot, where the big links of the non-redundant could be fragmented in smaller i-SAIRAS2020-Papers (2020) 5059.pdf links, therefore it is possible to fold these big links, re- quiring smaller volumes. The challenges can be found in the actuation, where for more links, more motors are required, which in turn results in a heavier kinematic chain. Further- more, the solution of the inverse kinematics (IK) prob- lem is complex and can result in having multiple solu- tions or none at all [21]. This represents a significant reduction in the operability of a redundant robot. 3.3 Modular Redundant Robot Figure 4: Joystick as input for simulation and operation. Modular redundant robots combine the benefits Left for the translation und right for the rotation and challenges of the redundant robot, plus the benefit of the re-configurability. This entails the ability to at- 4.2 The IK Solution tach or detach joints to an original kinematic chain, The IK is essential to simulate and operate robots. which can be integrated from 1-DOF to n-DOF.
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