Space station in-cabin teleoperation maintenance system and method based on flexible sensor

Abstract

The invention discloses a space station cabin teleoperation maintenance system and method based on a flexible sensor. The system is composed of a flexible multi-mode sensor array, an edge signal processing module, a satellite-ground communication link, a ground teleoperation platform and an in-cabin mechanical arm. The flexible sensor is directly attached to a to-be-maintained part, senses deformation, temperature, vibration and contact force in real time, and downloads the deformation, the temperature, the vibration and the contact force to the ground after compression coding. A ground operator completes high-immersion teleoperation in the force feedback glove and the three-dimensional visual environment, and an instruction is transmitted back to the mechanical arm in the cabin for execution; and the execution result passes the closed-loop verification of the flexible sensor again. According to the invention, the problems of high manual maintenance risk, difficulty in conformal installation of traditional rigid sensing, limited satellite-ground communication bandwidth and the like in a space station microgravity environment are solved, and'zero-intrusion 'sensing, low-bit-rate transmission and high-reliability teleoperation maintenance are realized.

Description

TECHNICAL FIELD

[0001] The present application relates to the technical field of on-orbit maintenance of spacecraft, and particularly relates to a space station cabin in-orbit remote maintenance system and method based on a flexible sensor. BACKGROUND

[0002] With the continuous development of the aerospace industry, long-term on-orbit operation and maintenance of spacecraft such as space stations has become a key issue. At present, space station maintenance mainly relies on astronauts to perform extravehicular or in-cabin manual operations. This approach has many drawbacks: first, astronauts face high safety risks. The space environment is complex and dangerous, and a slight mistake in extravehicular operation can cause serious accidents. Second, it is restricted by various factors, and the time window available for astronauts to perform maintenance is very limited, resulting in that maintenance tasks are often difficult to complete in a timely manner. Third, the precision of manual operation has certain limitations, and it is difficult to ensure high-quality maintenance results for some delicate and complex maintenance tasks.

[0003] In addition, traditional rigid sensors also have obvious shortcomings. Not only are they bulky and heavy, making it difficult to achieve good adhesion with complex curved surfaces of irregular shapes, but they also cannot simultaneously obtain multiple different physical quantity information, which greatly limits the efficiency and quality of maintenance work. Therefore, there is an urgent need for a light, conformal, multifunctional and low-power consumption sensing solution to support ground personnel to perform remote operation and complete delicate and complex maintenance tasks. SUMMARY

[0004] This invention proposes a space station in-cabin teleoperation and maintenance system and method based on flexible sensors. The system comprises a flexible multimodal sensor array, a signal processing and compression module, a space-to-ground communication link, a ground teleoperation platform, and an in-cabin maintenance execution terminal. The flexible multimodal sensor array integrates deformation sensing, temperature sensing, and pressure and vibration detection functions, employing serpentine copper wires, a graphene temperature-sensitive layer, and a micro-pyramid silicone dielectric structure to achieve accurate detection of multiple physical quantities. The signal processing module uses an FPGA chip for high-precision sampling and sparse coding-based compression processing, adding timestamps and sequence numbers to data packets to ensure efficient and complete data transmission. The space-to-ground communication link uses the Ku-band protocol to achieve remote data transmission at a rate of 2Mbps, with latency controlled within 600ms, and includes a data retransmission guarantee mechanism. The ground teleoperation platform provides a highly immersive operating experience through force feedback gloves and a 3D display terminal. The AI ​​decision unit performs rapid instruction inference based on a GPU, providing intelligent decision support for maintenance operations. The in-cabin maintenance execution terminal is equipped with a six-DOF lightweight robotic arm and a quick-change tool library, possessing high-precision execution and multi-task adaptability. The system's sensor is only 0.3mm thick and weighs only 2g. It has excellent fit and conformal capability. After compression, the data bandwidth is reduced to 100kbps, and the data integrity exceeds 99.9%. Through a closed-loop "perception-execution-re-perception" mechanism, the system achieves a repair success rate of over 97%, significantly reducing the risk of astronauts' extravehicular activity and improving the intelligence, safety, and execution efficiency of space maintenance missions. Attached Figure Description

[0005] To more clearly illustrate the technical solutions in the embodiments of this application, the accompanying drawings used in the description of the embodiments will be briefly introduced below. Obviously, the accompanying drawings described below are only some embodiments of this application. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0006] Figure 1 This is a flowchart illustrating a space station in-cabin remote operation and maintenance system and method based on flexible sensors provided by the present invention. Detailed Implementation

[0007] To make the objectives, technical solutions, and advantages of the embodiments of this application clearer, the technical solutions of the embodiments of this application will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of this application, not all embodiments. Based on the embodiments of this application, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of this application.

[0008] In space missions, such as space station extravehicular maintenance, planetary surface exploration and other operations, astronauts are in a closed and isolated state, and the conventional control and monitoring method faces many challenges. The space environment has many adverse factors such as extreme temperature difference, high energy particle radiation, electromagnetic interference, etc., so it is necessary to develop an intelligent sensing scheme that can adapt to the above special environment. The present application provides a manufacturing method of a high-sensitivity and high-anti-interference flexible sensor for extreme space environment, which can work stably for a long time under the conditions of temperature-100℃ to +120℃, high electromagnetic interference and radiation.

[0009] Step 101, the flexible sensor array is attached to the surface of the component to be repaired, and self-calibration is completed within 30 seconds, ensuring that the sensor can accurately perceive the initial state of the component and provide a reliable data basis for subsequent maintenance operations.

[0010] Step 102, the flexible multi-modal sensor array synchronously collects deformation, temperature, vibration and contact force signals, and the signal processing and compression module performs edge computing, feature extraction and compression coding on the collected signals to reduce the data volume, and then transmits the compressed data to the ground control center in real time through the satellite-ground communication link.

[0011] Step 103, the ground operator issues action instructions in the haptic scene reconstructed by the three-dimensional display terminal, while the AI maintenance decision unit locally performs rapid reasoning to assist in generating the next joint angle instruction sequence, and combines the operator's instructions and the AI decision results to form the final control signal.

[0012] Step 104, the control signal is uploaded to the in-cabin maintenance execution end through the satellite-ground communication link, and the six-degree-of-freedom lightweight mechanical arm receives the instruction and performs the corresponding maintenance action, such as fastening, plugging, cutting, coating, etc. In the execution process, the flexible sensor monitors the torque, temperature rise and other key parameters in real time to ensure that the operation is within the safe range.

[0013] Steps 105 and 106, determine whether the monitoring value exceeds the set threshold. If the monitoring value is abnormal, the ground end automatically triggers the protection program, the mechanical arm retreats to the safe position, and the action is re-executed; if the monitoring value is normal, the same flexible sensor array is used to verify the function of the maintenance result, and it is determined whether the maintenance task is completed. If it is qualified, the "task completed" flag is returned, and the maintenance process is ended.

[0014] The technical solutions of the present application are further illustrated by the following Example 1 and Comparative Example:

[0015] Example 1: Experiment cabinet cable plugging

[0016] A flexible sensor is arranged in a ring around the cable plug to monitor the plug force in real time during the cable plug-in and plug-out process, with a monitoring range of 5-15 N. When the cable plug-in and plug-out operation is performed, the snake-shaped copper wire and graphene temperature-sensitive layer in the sensor real-time perceive the force and temperature changes during the plug-in and plug-out process, and transmit signals to the signal processing and compression module. The processed and compressed data is transmitted to the ground control center through the satellite-ground communication link.

[0017] The ground operator can clearly feel the change of resistance during the plug-in and plug-out process through the force feedback gloves. The force feedback information is highly consistent with the actual force feeling during the plug-in and plug-out operation, so that the operator can accurately control the plug-in and plug-out force and speed of the mechanical arm. The three-dimensional display terminal provides intuitive visual assistance for the operator, showing the relative position and plug-in and plug-out state of the cable plug and socket, further improving the accuracy of the operation.

[0018] The mechanical arm accurately performs the cable plug-in and plug-out operation according to the joint angle instruction sequence generated by the ground operator's instruction and the AI decision unit. During the plug-in and plug-out process, the flexible sensor monitors parameters such as plug force and contact resistance in real time to ensure the smooth operation of the plug-in and plug-out operation and the reliability of the connection. The contact resistance is successfully reduced from 50 mΩ to 5 mΩ, verifying the success and effectiveness of the maintenance operation. The whole process fully demonstrates the application potential and advantages of the application in the fine maintenance task in the space station cabin.

[0019] Comparative Example 2: Space Station Solar Cell Panel Maintenance

[0020] When the solar cell panel of the space station is partially damaged and needs to be repaired, a flexible sensor array is first attached to the damaged area and its periphery of the panel. The sensor monitors physical quantity parameters such as deformation, temperature, vibration and contact force of the panel in real time, and transmits data to the signal processing and compression module. The signal processing and compression module processes and compresses the data, and then transmits the data to the ground control center through the satellite-ground communication link.

[0021] After receiving the data, the three-dimensional display terminal of the ground control center reconstructs the three-dimensional tactile scene of the solar cell panel, and intuitively displays information such as the location, shape and damage degree of the damaged area. The operator issues maintenance action instructions through the force feedback gloves according to the visual information and force feedback information on the three-dimensional display terminal. The AI decision unit generates a joint angle instruction sequence according to the instructions to control the movement of the cabin mechanical arm.

[0022] The mechanical arm carries special maintenance tools such as wire cutters, glue injection nozzles, etc., and moves to the damaged area according to the remote instructions of the ground experts. According to the actual situation, the mechanical arm may need to use wire cutters to cut off the damaged wires or connectors first, then use the glue injection nozzle to seal the damaged part with glue, and finally use the cross batch or one word batch to tighten the fixing screws of the solar panel. During the entire maintenance process, the flexible sensor monitors various physical parameters in real time to ensure the smooth progress of the maintenance operation and the reliability of the maintenance quality.

[0023] When the maintenance is completed, the sensor detects the solar panel again, including whether the deformation returns to normal, whether the temperature distribution is uniform, whether the vibration is reduced, and whether the contact force meets the requirements, etc. If all parameters are within the normal range, a "task completed" flag is returned to the ground control center through the star-ground communication link, indicating that the maintenance task is successfully completed. Otherwise, the ground control center will analyze the problem and take appropriate remedial measures according to the sensor feedback information until the maintenance is qualified.

[0024] Comparative Example 3: Space Station Life Support System Component Maintenance

[0025] For key components in the space station life support system, such as air filters, water circulation treatment devices, etc., when a failure occurs and needs to be repaired, the remote operation maintenance system of the present application can also be used for maintenance. First, the flexible sensor array is attached to the surface of the component to be maintained, ensuring that the sensor is tightly attached to the component and can accurately sense various physical parameters of the component.

[0026] The sensor collects signals such as deformation, temperature, vibration, and contact force in real time, and the signal processing and compression module processes and compresses the signals, then transmits the data to the ground control center through the star-ground communication link. The ground control center reconstructs the three-dimensional haptic scene of the component through a three-dimensional display terminal, providing intuitive visual information for the operator. The operator uses force feedback gloves to issue maintenance instructions based on visual and tactile information, and the AI decision unit generates joint angle instruction sequences to control the in-cabin mechanical arm to perform corresponding maintenance actions.

[0027] The mechanical arm carries corresponding tools such as wrenches, screwdrivers, etc. according to the instructions, and performs disassembly, replacement, or repair operations on the faulty component. During the operation, the flexible sensor monitors the state changes of the component in real time to ensure the accuracy and safety of the maintenance operation. For example, during disassembly, monitor whether the disassembly force is appropriate to avoid excessive force that may damage the component; when replacing the new component, monitor whether the new component is installed in place and whether the contact is good, etc.

[0028] After the maintenance, the function of the component is verified by the flexible sensor to check whether it returns to normal working state. If the verification is qualified, the "task completed" sign is returned to the ground control center; if the verification is not qualified, the above maintenance process is repeated until the maintenance is successful. This closed-loop verification mechanism ensures the maintenance quality and reliability of the life support system components, and guarantees the life safety and quality of astronauts in the space station.

Claims

1. A remote operation and maintenance system for a space station based on flexible sensors, characterized in that, include: A flexible multimodal sensor array is attached to the surface of the target to be repaired to simultaneously collect deformation, temperature, vibration and contact force signals; The signal processing and compression module, located near the cabin, performs edge computing, feature extraction, and compression encoding on the acquired signals using a low-power FPGA. The space-to-ground / inter-satellite communication link transmits compressed sensor data to the ground control center in real time via UDP protocol; the ground teleoperation platform includes force feedback gloves, a 3D display terminal, and an AI maintenance decision unit; the in-cabin maintenance execution terminal consists of a six-degree-of-freedom lightweight robotic arm and a quick-change tool library, receiving ground commands to complete tightening, insertion, shearing, and coating actions; the closed-loop monitoring unit collects the execution results again through the same flexible sensor array, forming a "perception-execution-re-perception" closed loop.

2. The system according to claim 1, wherein the flexible multimodal sensor array consists of three layers: a 0.1mm thick polyimide substrate layer, a serpentine copper / graphene composite conductive layer for deformation and temperature detection; and a micro pyramid silicone dielectric layer for pressure and vibration detection. The three layers are encapsulated by low-temperature epoxy adhesive hot pressing, and the overall bending radius is ≤5mm. According to the system of claim 1, the AI ​​maintenance decision unit adopts a lightweight Transformer network, performs local inference on the ground, with an inference latency of <50ms, and generates the next joint angle instruction sequence.

3. A method for remote operation and maintenance inside a space station based on the system described in any one of claims 1-3, characterized in that, include: A flexible sensor array is attached to the surface of the part to be repaired, completes self-calibration within 30 seconds, collects and compresses multimodal data, reducing the bit rate to 5% of the original data; The ground-based system reconstructs a 3D tactile scene in real time. Operators issue action commands through force feedback gloves, and the robotic arm inside the cabin executes the actions. Flexible sensors monitor torque and temperature rise in real time. When the monitored values ​​exceed the set threshold, the ground-based system automatically triggers a protection program, and the robotic arm retracts. After completion, the system performs functional verification through the same sensor array. If it passes the verification, it sends back a "task completed" flag.

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