Panel satellite adaptive stacking system and method

Abstract

The invention provides a panel satellite self-adaptive stacking system and method which are applied to the technical field of satellite general assembly, an intelligent closed-loop control system is formed through a double-layer frame structure and integrated sensing, leveling, clamping and crown block cooperative control modules, and the real-time state of a satellite is obtained through a sensing module; the leveling module actively eliminates satellite attitude deviation through differential adjustment on the basis of a centroid model, and the crown block cooperative control module performs active vibration suppression through a prediction algorithm in the moving process, so that high-precision, self-adaptive and unmanned operation of the whole process of grabbing, leveling, moving and stacking of the flat plate satellite is realized; and the operation standardization is obviously improved, the safety risk is reduced, and the high-efficiency and reliability requirements of batch production of spacecrafts are met.

Description

Technical Field

[0001] This application relates to the field of satellite assembly technology, specifically to a flat-panel satellite adaptive stacking system and method. Background Technology

[0002] Currently, low-Earth orbit (LEO) satellite constellations are entering a new phase of routine and intensive networking, which places higher demands on the efficiency and precision of satellite assembly and stacking. Taking the "Qianfan constellation" as an example, it plans to deploy 15,000 LEO satellites by 2030, requiring an average of over 2,000 launches per year. Traditional operational methods can no longer support such a high-intensity deployment mission.

[0003] In plate-type satellite stacking projects, attitude alignment control is directly related to the positioning accuracy and structural safety of onboard precision equipment. Because stacking is a relatively recent development, domestic satellite manufacturers such as Juntian Aerospace, Aerospace Dongfanghong Satellite, and Changguang Satellite generally use vertical lifting for satellite hoisting and stacking. This relies on manual visual command and manual adjustment of lifting tools (such as turnbuckles) to accommodate satellites of different weights and sizes. This approach suffers from limited adjustment range, low accuracy, and poor consistency. For example, stacking the 18 Qianfan satellites requires multiple people working together, relying on visual methods for collision prevention. Traditional lifting tools, lacking adaptive adjustment capabilities, are prone to swaying or even collisions when the satellite's center of mass shifts.

[0004] Although some solutions have attempted to shift to satellite horizontal lifting, such as a spacecraft horizontal adjustment hoisting device proposed by the Beijing Satellite Environmental Engineering Research Institute, they still face problems such as weak satellite compatibility and low efficiency in the adjustment process.

[0005] Overall, existing stacking solutions rely heavily on human experience and multi-position collaboration, resulting in systemic bottlenecks such as difficulty in precision control, low operational efficiency, and high human-machine safety risks. They cannot meet the urgent need for batch, high-precision, and high-efficiency stacking of thousands of satellites annually.

[0006] Therefore, a new adaptive stacking scheme for flat-panel satellites is needed. Summary of the Invention

[0007] In view of this, the embodiments of this specification provide a flat-panel satellite adaptive stacking system and method, which comprehensively overcomes the key bottleneck problems existing in current satellite stacking operations, such as high degree of manual intervention, difficulty in ensuring operational accuracy, and low efficiency.

[0008] The embodiments in this specification provide the following technical solutions: This specification provides an embodiment of a flat-panel satellite adaptive stacking system, comprising: The double-layer frame includes an upper leveling assembly connected to the overhead crane, and a lower tooling assembly for supporting the flat-panel satellite. The sensing module, installed in the lower tooling assembly, is used to acquire the real-time pose and vibration signals of the flat-panel satellite; A clamping module, installed on the lower tooling assembly, is used to perform flexible gripping and release of the flat-panel satellite; The leveling module is communicatively connected to the sensing module and the upper-level leveling component. It is used to obtain the centroid offset of the flat-panel satellite based on the real-time pose and the pre-stored satellite centroid distribution model, and drive the upper-level leveling component to perform differential adjustment based on the centroid offset to level the flat-panel satellite to the target horizontal attitude. The overhead crane collaborative control module is communicatively connected to the sensing module and is used to plan the crane's movement trajectory based on the target stacking point information. During the crane's movement, based on the real-time pose and vibration signals provided by the sensing module, the module uses a predictive control algorithm to drive the crane's vibration reduction link for active vibration suppression control.

[0009] This specification also provides an adaptive stacking method for flat-panel satellites, applied to the aforementioned adaptive stacking system for flat-panel satellites, the adaptive stacking method for flat-panel satellites comprising: The clamping module is used to grasp the flat-panel satellite; The sensing module acquires the real-time pose and vibration signals of the clamped flat-panel satellite. The leveling module obtains the centroid offset of the flat-panel satellite based on the real-time pose and the pre-stored satellite centroid distribution model, and drives the upper-level leveling component to perform differential adjustment based on the centroid offset to level the flat-panel satellite to the target horizontal attitude. The crane collaborative control module plans the crane's movement trajectory based on the target stacking point information; and during the crane's movement, based on the real-time pose and vibration signals provided by the sensing module, the crane's vibration reduction link is driven by a predictive control algorithm to perform active vibration suppression control until the flat-panel satellite is moved to the target stacking point and placed.

[0010] Compared with the prior art, the beneficial effects that at least one technical solution adopted in the embodiments of this specification can achieve include at least: This application integrates clamping, sensing, leveling, and crane collaborative control modules into a two-layer framework, realizing full automation and intelligence of the flat-panel satellite process from grasping and leveling to stacking. It can autonomously calculate the centroid offset based on real-time pose and pre-stored models and complete high-precision dynamic leveling. At the same time, it actively suppresses swaying through predictive algorithms during crane transfer, completely overcoming the problems of low efficiency, poor accuracy, and insufficient safety of manual operation. It significantly improves the accuracy, efficiency, and reliability of stacking operations, fills the gap in domestic automated stacking equipment, helps my country achieve "leapfrog development" in the construction of low-Earth orbit constellations, and promotes the transformation and upgrading of satellite manufacturing from "laboratory customization" to "factory mass production". Attached Figure Description

[0011] To more clearly illustrate the technical solutions of the embodiments of this application, the drawings used in the embodiments will be briefly introduced below. Obviously, the 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.

[0012] Figure 1 This is a schematic diagram of the structure of a flat-panel satellite adaptive stacking system according to this application; In the diagram: 1. Overhead crane; 2. Upper leveling assembly; 3. Lower tooling assembly; 4. Clamping module. Detailed Implementation

[0013] The embodiments of this application will now be described in detail with reference to the accompanying drawings.

[0014] The following specific examples illustrate the implementation of this application. Those skilled in the art can easily understand other advantages and effects of this application from the content disclosed in this specification. Obviously, the described embodiments are only a part of the embodiments of this application, and not all of them. This application can also be implemented or applied through other different specific embodiments, and the details in this specification can also be modified or changed based on different viewpoints and applications without departing from the spirit of this application. It should be noted that, in the absence of conflict, the following embodiments and features in the embodiments can be combined with each other. Based on the embodiments in this application, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of this application.

[0015] It should be noted that various aspects of embodiments within the scope of the appended claims are described below. It will be apparent that the aspects described herein can be embodied in a wide variety of forms, and any particular structure and / or function described herein is merely illustrative. Based on this application, those skilled in the art will understand that one aspect described herein can be implemented independently of any other aspect, and two or more of these aspects can be combined in various ways. For example, any number and aspects set forth herein can be used to implement the device and / or practice the method. Additionally, this device and / or method can be implemented using structures and / or functionalities other than one or more of the aspects set forth herein.

[0016] It should also be noted that the illustrations provided in the following embodiments are only schematic representations of the basic concept of this application. The drawings only show the components related to this application and are not drawn according to the actual number, shape and size of the components in the actual implementation. In the actual implementation, the form, quantity and proportion of each component can be arbitrarily changed, and the layout of the components may also be more complex.

[0017] Additionally, specific details are provided in the following description to facilitate a thorough understanding of the examples. However, those skilled in the art will understand that practice can be carried out without these specific details.

[0018] In current satellite stacking operations, to ensure accuracy and operational safety, it is necessary to strictly follow the multi-position collaborative process. Before the operation begins, the on-site commander organizes a safety briefing meeting to clarify the stacking sequence and emergency plan, and conducts a comprehensive inspection of the overhead crane, aerial work platform, and lifting equipment, including key indicators such as: hoisting rope wear ≤7%, aerial work platform load capacity ≥300kg, and prepares tools such as feeler gauges; the overall structure confirms the satellite stacking order, inspects the lifting blocks and shackles, and the satellite operation team installs anti-falling lifting blocks and removes the grounding device.

[0019] During installation, the hoisting supervisor directs the overhead crane to center its position, connects the lifting gear and shackles, and lifts it to 100mm off the ground, pausing for one minute to verify uniform force distribution. The assembly supervisor guides the adjustment of the turnbuckles to ensure the satellite's end face is level, while an anti-sway rope is attached to one corner of the satellite to ensure the sway amplitude does not exceed 10°. During the docking phase, when the satellite descends to 500mm from the target position, the overhead crane is switched to micro-motion mode, with the operating speed controlled within 5mm / s. The aerial work platform operator supports the edge of the satellite and pushes it into the docking position, using feeler gauges to measure the axial clearance of the load-bearing columns at multiple points, controlling the range between 0.1–0.3mm. After removing the lifting blocks, a second supervisor measures the limit switch clearance, ranging from 0.5–1mm. The on-site quality supervisor inspects the docking gap, requiring it to be no greater than 0.2mm. The entire process is recorded and archived via multimedia. After stacking is completed, the equipment is cleaned and an inspection form is filled out. Finally, the transfer team completes the satellite grounding and the support vehicle retrieval.

[0020] This traditional work mode, which heavily relies on visual judgment and manual adjustment, has revealed systemic problems in practice, including low efficiency, insufficient accuracy, and significant safety hazards. Specifically: leveling effectiveness is limited by operator experience, easily leading to excessive deviations; the use of aerial work platforms requires close collaboration among multiple people, posing risks of collisions and pinching injuries; gap measurement results are affected by subjective human factors, easily causing abnormal structural stress; multi-position collaboration relies on verbal instructions, and paper-based records make effective data traceability and analysis difficult.

[0021] In view of this, the inventors, through in-depth research and improvement of the stacking method, discovered that domestic satellite manufacturers generally adopt a vertical lifting method for satellites. Their general satellite lifting devices mostly adopt a design of main longitudinal beams, main transverse beams, and movable sliders (with interchangeable transverse beam locking points, electric push rod cross slides, and disassembly / assembly adapters, etc.). By adjusting the spacing between lifting points and the length of the slings (such as turnbuckle adjustment), limited adaptation to satellites of different weights and sizes can be achieved. Although some solutions have attempted to explore horizontal lifting, such as a spacecraft horizontal adjustment lifting device proposed by the Beijing Satellite Environmental Engineering Research Institute, which includes a lifting ring assembly, an XY worktable, a lifting beam, and slings, and the lifting ring assembly includes a lifting ring for connection to the crane hook, an intermediate load-bearing structure, and a two-dimensional tilt sensor for measuring the tilt angle between the crane and the hook; however, this solution has obvious limitations such as insufficient satellite compatibility and low adjustment efficiency.

[0022] Ultimately, the main reason for the difficulty in adjusting and leveling existing stacking methods is that the carrier size on which measurement and adjustment depend is too small. When the rope is long, the sensors on the carrier are not sensitive, and the accuracy of the center of gravity adjustment is low, making it difficult to meet the requirements of high-precision stacking.

[0023] Based on this, the embodiments of this specification propose an adaptive stacking system for flat-panel satellites. The overall concept is as follows: through a double-layer frame structure, sensing, leveling, clamping, and crane-coordinated control modules are integrated to form an intelligent closed-loop control system. The sensing module obtains the real-time status of the satellite, and the leveling module actively eliminates the satellite's attitude deviation through differential adjustment based on the center of mass model. The crane-coordinated control module actively suppresses vibration during the movement process through predictive algorithms. This achieves high-precision, adaptive, and unmanned operation of the entire process of flat-panel satellites from grasping, leveling, moving, and stacking, significantly improving the standardization of operations, reducing safety risks, and meeting the high efficiency and reliability requirements of mass production of spacecraft.

[0024] The technical solutions provided by the various embodiments of this application are described below with reference to the accompanying drawings.

[0025] like Figure 1 As shown in the figure, this specification provides a flat-panel satellite adaptive stacking system, including: The double-layer frame includes an upper leveling assembly 2 connected to the overhead crane 1, and a lower tooling assembly 3 for supporting the flat panel satellite; The sensing module, installed on the lower tooling component 3, is used to acquire the real-time pose and vibration signals of the flat-panel satellite; The clamping module 4, installed on the lower tooling assembly 3, is used to perform flexible gripping and release of the flat-panel satellite; The leveling module is communicatively connected to the sensing module and the upper-level leveling component 2. It is used to obtain the centroid offset of the flat-panel satellite based on the real-time pose and the pre-stored satellite centroid distribution model, and drive the upper-level leveling component 2 to perform differential adjustment based on the centroid offset to level the flat-panel satellite to the target horizontal attitude. The crane collaborative control module is communicatively connected to the sensing module and is used to plan the movement trajectory of the crane 1 based on the target stacking point information. During the movement of the crane 1, based on the real-time pose and vibration signals provided by the sensing module, the crane 1 vibration reduction link is driven by a predictive control algorithm to perform active vibration suppression control.

[0026] During implementation, the sensing module (i.e., the intelligent measurement and positioning subsystem) is responsible for collecting the precise position (X, Y, Z) and attitude (horizontal tilt) of the flat-panel satellite in real time, as well as the amplitude and frequency of the swaying generated by the satellite during movement, and monitoring whether it is in a horizontal state (horizontal tilt).

[0027] The clamping module 4 is responsible for the final execution and contact, "gripping" the satellite in a way that combines rigidity and flexibility, ensuring that it neither slips nor is damaged. It has force sensing and flexible adaptive capabilities to ensure that the contact process is safe and undamaged.

[0028] The leveling module is responsible for eliminating the static and quasi-static tilt of the satellite. It receives the pose data from the sensing module and quickly calculates the current centroid offset by calling the pre-stored satellite centroid distribution model. Based on the centroid offset, it drives the upper leveling components (usually multiple servo winches) to perform differential adjustment, that is, by asynchronously raising and lowering the length of each sling, the satellite is adjusted to a horizontal attitude.

[0029] The crane-cooperative control module is responsible for the movement planning and smooth movement of the entire system. It plans an optimal movement trajectory that balances efficiency and stability based on the target stacking point information. During the movement, it receives vibration signals from the sensing module in real time, uses predictive control algorithms to calculate the compensation force required to suppress swaying in advance, and drives the crane to move in the opposite direction to actively "cancele" the swaying. This solves the key bottleneck problems in current satellite stacking operations, such as high degree of human intervention, difficulty in ensuring operational accuracy, and low efficiency.

[0030] This application focuses on the core aspects of satellite stacking operations, tackling key technical challenges such as automatic positioning and alignment technology, flexible clamping mechanism, dynamic attitude leveling algorithm, and efficient collaborative control with the overhead crane system, forming a fully unmanned operation capability covering the entire process from target recognition, path planning, precise execution to status feedback.

[0031] In some embodiments, the sensing module includes a 3D LiDAR and an industrial vision camera; The real-time pose of the flat-panel satellite is generated by fusing the point cloud data from the lidar and the image data from the industrial vision camera.

[0032] In implementation, high-precision, multi-modal sensor fusion is the core technology. By integrating a 3D LiDAR and an industrial-grade vision camera on a lower-level tooling platform, real-time scanning and fusion positioning of the flat-panel satellite's outline and feature points are achieved. The 3D LiDAR rapidly constructs a satellite outline model using point cloud data, maintaining anti-interference and stable measurement performance under different lighting conditions. The vision camera captures the satellite's surface coding, markings, and detailed features, providing two-dimensional texture reinforcement for the LiDAR point cloud. Through collaborative processing of deep learning and traditional geometric registration algorithms, high-precision pose information with a positioning accuracy ≤0.5mm and an attitude measurement error ≤0.01° is generated.

[0033] This embodiment is based on the fusion positioning of 3D LiDAR and visual camera, combined with real-time tilt angle feedback from a high-precision angle sensor, to achieve adaptive adjustment of satellite attitude.

[0034] In some embodiments, the sensing module further includes: a process closed-loop unit; The process closed-loop unit is used to identify the coded identifier of the flat-panel satellite through the industrial vision camera; The encoded identifier is compared with a preset stacking sequence. If the comparison is inconsistent, or if the real-time pose is detected to exceed a preset deviation threshold, a control command is triggered to pause the stacking operation and issue an alarm. And / or, record and upload the status of key operational steps for grasping, clamping, leveling and placing the horizontal satellite.

[0035] During implementation, the system incorporates a closed-loop process layer. A vision camera identifies and numbers the QR codes or laser markings on the sides of the satellite, and compares this information in real-time with stacking sequence information in a database. When a sequence error or pose deviation exceeds a set threshold, an alarm is immediately triggered, and subsequent actions are paused to ensure zero-error operation.

[0036] It can also record the status of each satellite's key steps, such as grabbing, placing, leveling, clamping, and resetting, and upload the data to the central monitoring platform to achieve full-process traceability and offline data analysis.

[0037] In conjunction with the above embodiments, the central monitoring platform also provides a visual interface to display the current workstation status, remaining tasks, historical records, and alarm logs, supporting remote operation and maintenance and decision support.

[0038] In some embodiments, the sensing module further includes a tilt sensor for forming a real-time feedback loop; The real-time feedback loop is used to trigger the leveling control module to start the dynamic compensation process when the detected tilt angle exceeds the preset tilt angle threshold.

[0039] Specifically, the sensing module also includes a tilt sensor, forming a real-time tilt sensor feedback loop. When a slight tilt is detected due to a shift in the center of gravity or slack in the sling, the system will immediately trigger a dynamic compensation process to provide reliable input for subsequent leveling and clamping operations.

[0040] In some embodiments, the leveling module employs a dynamic compensation algorithm based on robust adaptive control; The dynamic compensation algorithm combines second-order prediction and model tracking control strategies to ensure that the error of the final attitude after leveling is controlled within a certain range. Within.

[0041] During implementation, the centroid shift that may occur during the hoisting, transportation and stacking of flat-panel satellites can be compensated by a dynamic compensation algorithm based on robust adaptive control theory. By establishing centroid distribution models for different satellite models in advance, such as "Qianfan" and "Qianfan II", and combining them with real-time measured pose data, the actual shift can be identified online and the upper-level winch assembly can be driven to perform differential adjustment.

[0042] The dynamic compensation algorithm can adopt a strategy that combines second-order prediction with model tracking control (MPC). On the one hand, it ensures a fast response to compensation (leveling response time ≤ 120s), and on the other hand, it suppresses overshoot and oscillation during the compensation process, so that the final attitude error is controlled within ±0.02°.

[0043] In some embodiments, during the dynamic leveling process, the system also monitors the tension of the slings and the load distribution in real time to ensure that the entire structure maintains sufficient safety margin under a load of thousands of kilograms.

[0044] In some embodiments, the clamping module includes an internally supported gripper; The internal support claw has a flexible polymer pad on its claw surface, and a micro-motion coupling mechanism is integrated on the claw tooth contact surface to adapt to the microscopic unevenness of the flat satellite surface. The clamping module is configured to: during the clamping process, first complete the initial closure in position control mode, and then switch to force control mode to use force sensor feedback to lock the target clamping force.

[0045] In practice, the clamping module includes an internally supported gripper, such as an internally supported three-jaw mechanical gripper, which has an adjustable clamping range of 50-200mm and a programmable clamping force of 50-500N.

[0046] To balance high clamping rigidity with protection of the satellite's surface coating, the claw surface is designed with multiple layers of flexible polymer pads to prevent scratching the paint. A micro-coupling mechanism is integrated into the claw tooth contact surface, allowing for automatic tilting within a small range of ±1° to adapt to microscopic surface unevenness. The clamping process first completes the initial closure in position control mode, and then enters force control mode, using force sensor feedback to lock the target clamping force, avoiding excessive pressure on the satellite's outer shell.

[0047] In some embodiments, the internally supported gripper is also equipped with a displacement sensor; The displacement sensor is used to detect the contact distance between the claw and the flat satellite. When the contact distance is detected to be less than the preset contact distance, the crane is controlled to switch to micro-motion mode.

[0048] Specifically, when the contact distance between the claw and the satellite is less than 1mm, it automatically switches to micro-motion mode to achieve high-precision contact positioning and ensure that it maintains a firm grip even when the crane moves down or there is vibration interference.

[0049] In some embodiments, a dedicated wireless communication link is established between the overhead crane cooperative control module and the overhead crane; The communication latency of the dedicated wireless communication link is controlled within 50ms. The active vibration damping control is configured as follows: The amplitude is suppressed to ≤0.5° under full load conditions; Under abnormal operating conditions, switch to emergency braking mode and activate the secondary energy absorption and vibration damping device within 0.1 seconds; The abnormal operating conditions include at least one of the following: receiving an emergency stop signal from the overhead crane, detecting vibration amplitude exceeding a preset safety threshold, or sling tension exceeding a preset safety range.

[0050] During implementation, to eliminate the risk of inertial swaying caused by the long-distance movement of the overhead crane in the stacking area, a dedicated wireless communication link was established between the overhead crane and the execution platform, with communication latency controlled within ≤50ms. Based on the received real-time pose and vibration signals, the controller, combined with predictive control algorithms, drives the overhead crane vibration damping link to actively suppress vibration, reducing the amplitude to ≤0.5° under full load conditions. When encountering sudden conditions (such as emergency stop or external impact), the system will switch to emergency braking mode within ≤0.1s and activate the secondary energy absorption and vibration damping device to quickly attenuate the residual oscillation amplitude to an acceptable range.

[0051] In addition, the overhead crane path planning module will automatically generate the optimal motion trajectory based on the current stacking station information, taking into account both work efficiency and vibration safety.

[0052] In some embodiments, the lower-level tooling components employ modular interfaces to adapt to adapters for different satellite models.

[0053] During implementation, the lower-level tooling components use modular interfaces to support quick replacement of satellite adapters, such as for use with Qianfan and Qianfan II. This layer takes into account both measurement and positioning.

[0054] This application integrates multiple advanced sensing technologies to construct a multi-sensor collaborative positioning system based on 3D LiDAR and visual information, enabling high-precision positioning operations under complex working conditions. It introduces a centroid offset adaptive compensation algorithm and a wireless low-latency communication mechanism to improve attitude stability and control response under dynamic load and suspension conditions. Furthermore, it enhances the system's flexibility and maintainability through a modular double-layer frame structure design.

[0055] Based on the same inventive concept, this application also provides a planar satellite adaptive stacking method, applied to the aforementioned planar satellite adaptive stacking system, the planar satellite adaptive stacking method comprising: The clamping module is used to grasp the flat-panel satellite; The sensing module acquires the real-time pose and vibration signals of the clamped flat-panel satellite. The leveling module obtains the centroid offset of the flat-panel satellite based on the real-time pose and the pre-stored satellite centroid distribution model, and drives the upper-level leveling component to perform differential adjustment based on the centroid offset to level the flat-panel satellite to the target horizontal attitude. The crane collaborative control module plans the crane's movement trajectory based on the target stacking point information; and during the crane's movement, based on the real-time pose and vibration signals provided by the sensing module, the crane's vibration reduction link is driven by a predictive control algorithm to perform active vibration suppression control until the flat-panel satellite is moved to the target stacking point and placed.

[0056] During implementation, after the system is started, the first step is to use the sensing module to perform non-contact scanning and identification of the flat-panel satellite that is still in the initial position, to obtain the overall outline and coding information of the flat-panel satellite. The pose information is then transmitted to the controller and dynamically leveled to ensure that no collision occurs during subsequent grasping and that the satellite can be accurately moved to the grasping point.

[0057] After reading the satellite's encoded information, it is checked against the preset stacking sequence to prevent incorrect stacking order from the source.

[0058] The system then enters the grasping and upgrading phase. Under the dual closed-loop control of position and force, the clamping module flexibly grasps the flat-panel satellite and initially lifts it. The satellite is then raised to an intermediate height and hovered. At this position, the system checks the stability of the grasp and the attitude of the satellite again, correcting any minor deviations that may occur during the grasping process, thereby ensuring the safety of subsequent long-distance movement.

[0059] During the movement and lowering of the crane, the vibration suppression algorithm works continuously to actively suppress "swaying" and avoid collisions with the satellites already stacked below.

[0060] To address the potential centroid shift that may occur during the hoisting, transport, and stacking of flat-panel satellites, a leveling module obtains the centroid shift of the flat-panel satellite based on the real-time pose and a pre-stored satellite centroid distribution model. The module then drives the upper-level leveling component to perform differential adjustment based on the centroid shift, thereby leveling the flat-panel satellite to the target horizontal attitude. During the placement and reset phase, under the low-latency anti-sway control of the overhead crane, the execution platform slowly moves down to the target stacking point, the clamping module is released and quickly retracted, and then the platform returns to the initial position. The entire process is automatically repeated.

[0061] In some embodiments, when vision or pose verification fails, the system immediately issues an error signal and stops operation. With an emergency stop response time of ≤0.1s, the local or remote interface prompts the operator to check, and work can only continue after confirmation. To ensure efficient maintenance and updates, the modular framework design allows for rapid replacement of key components (such as sensor units and gripper assemblies), supporting hot-swapping and online diagnostics.

[0062] This application achieves precise satellite alignment through 3D vision real-time positioning, AI algorithm leveling, and multi-sensor fusion control technology. At the same time, it replaces manual support with automated equipment, reducing safety risks and improving operational standardization, thus meeting the high efficiency and reliability requirements of mass production of spacecraft.

[0063] Below is another example of a flat-panel satellite adaptive stacking system, which combines the previous examples to form an illustrative example. This flat-panel satellite adaptive stacking system ensures that the entire process from design, trial production to verification is controllable and efficient through a systematic implementation in four stages.

[0064] Requirements analysis and system design phase: Taking the "Qianfan Constellation" as the research object, this study conducted an in-depth investigation into the shape, mass, center of mass distribution, and payload characteristics of different batches of satellites, combined with factors such as the travel, speed, acceleration, braking performance, and on-site environment (space constraints, temperature and humidity, electromagnetic interference, etc.) of various types of overhead cranes. Based on the investigation results, the system's functional requirements and performance indicators were clarified, including positioning accuracy, leveling response speed, load capacity, anti-sway amplitude, reliability, and human-machine interface requirements. Subsequently, finite element simulations of the double-layer frame's stress structure were performed using CAD / CAE software to evaluate the stiffness and safety margin under kilogram-level loads and dynamic leveling conditions. Based on simulation feedback, the cross-sections and materials of the vertical main beam, transverse support beams, and connecting nodes were optimized. In parallel, a complete set of kinematic and dynamic models was established to verify the feasibility of coordinated action of the winch, slide, and gripper. A control logic prototype was built in MATLAB / Simulink to preliminarily verify the control framework and timing process of multi-sensor fusion positioning, adaptive compensation, and overhead crane linkage strategies.

[0065] Prototype Manufacturing and Integration Phase: Immediately after design freezing, prototype component manufacturing begins. First, key components of the double-layer frame are manufactured according to the optimized plan, with surface treatment and assembly benchmark grinding to ensure the geometric accuracy of the overall structure. Simultaneously, high-precision winches, slides, three-jaw grippers, and sensor brackets are procured or customized. Next, 3D LiDAR, industrial cameras, and high-precision tilt sensors are deployed in the lower tooling area, with electrical installation and cable management completed to ensure signal stability of the sensor network under different postures and displacement conditions. Meanwhile, the software team develops communication protocols and control algorithms, first deploying low-latency links based on dedicated wireless frequency bands in a laboratory environment to gradually verify indicators such as latency ≤50ms. Based on this, a crane collaborative control algorithm is developed and integrated, interfaced with the control platform, and an integrated process from multi-sensor data acquisition, filtering and fusion to control command issuance is achieved. Upon completion of this phase, a hardware prototype and a preliminary control platform ready for the first round of integration and debugging should be available.

[0066] Testing and Optimization Phase: After the prototype is assembled, a series of specialized tests will be conducted in a controlled laboratory environment, including: Positioning accuracy test: Standard gauge blocks and calibration targets were used for comparative measurement to verify the measurement error distribution of the LiDAR + vision fusion algorithm under different lighting and background conditions; Dynamic leveling performance test: Simulating the center of mass offset condition, by applying different eccentric loads, the system's leveling response time and residual tilt angle in steady state are measured; Anti-sway performance test: Vibration sensor data was collected in real time during the crane's full-load operation, emergency stop, and speed change to evaluate the effectiveness of the crane's vibration reduction link and algorithm in suppressing amplitude; Durability and reliability testing: Conduct at least 500 continuous cycle operation tests and record the wear and failure rate of key components (winch, slide, gripper); Functional closed-loop testing: Simulate the entire work process to verify the accuracy and fault tolerance of visual number recognition and stacking order verification.

[0067] Based on the test results, the software team iteratively optimized the positioning fusion and compensation algorithm parameters, while the mechanical team fine-tuned the gripper stroke and clamping force curves, and improved the frame connection stiffness and damping characteristics. All optimizations were documented in version logs, and the effectiveness of the changes was verified through regression testing.

[0068] Application Verification and Expansion Phase: A small-scale production line was selected in a factory workshop or launch site environment to organize and complete the stacking verification of 18 "Qianfan" satellites. This process not only tested the system's collaborative efficiency under real production cycles but also considered the ergonomics of the user interface and the convenience of on-site operation and maintenance. Stress tests were conducted on the on-site environment, including dust, temperature and humidity fluctuations, and electromagnetic interference. Weather resistance enhancements (sealing and anti-corrosion treatment) and industrial-grade electromagnetic compatibility improvements were made to the system as needed. After completing batch verification, the design of the second-phase launch site adaptation scheme was initiated: this included optimizing the standardization specifications of tooling interfaces, deploying mobile portable system modules, and developing on-site rapid installation and disassembly procedures and emergency maintenance manuals. Simultaneously, preliminary market assessments and user training plans were conducted to lay the foundation for subsequent multi-site promotion and modular productization. At this point, the entire project achieved a closed-loop implementation from requirements to design, from prototype to batch verification, and from laboratory to on-site application, fully achieving the project objectives.

[0069] This embodiment ensures the timely and high-quality delivery of the flat-panel satellite adaptive stacking system through a systematic methodology, iterative development process, and rigorous testing and verification, and ultimately enables mass field application and subsequent functional expansion.

[0070] In terms of system integration and functional verification, this application will build a reproducible verification environment based on real-world application scenarios to comprehensively verify the system's performance indicators in terms of stacking accuracy, operational efficiency, reliability, and environmental adaptability.

[0071] This application significantly enhances the intelligence and automation level of satellite manufacturing and launch processes, reduces intervention in manual operations, supports the batch and large-scale deployment of satellites, and has the potential to be applied to multiple scenarios such as launch sites and space assembly plants, providing solid technical support and core equipment guarantee for the efficient implementation of my country's space missions and the development of the commercial space industry.

[0072] In this specification, the same or similar parts between the various embodiments can be referred to mutually. Each embodiment focuses on describing the differences from other embodiments. In particular, the descriptions of the embodiments described later are relatively simple, and relevant parts can be referred to the descriptions of the foregoing embodiments.

[0073] The above description is merely a specific embodiment of this application, but the scope of protection of this application is not limited thereto. Any variations or substitutions that can be easily conceived by those skilled in the art within the technical scope disclosed in this application should be included within the scope of protection of this application. Therefore, the scope of protection of this application should be determined by the scope of the claims.

Claims

1. A flat-panel satellite adaptive stacking system, characterized in that, include: The double-layer frame includes an upper leveling assembly connected to the overhead crane, and a lower tooling assembly for supporting the flat-panel satellite. The sensing module, installed on the lower tooling component 3, is used to acquire the real-time pose and vibration signals of the flat-panel satellite; A clamping module, installed on the lower tooling assembly, is used to perform flexible gripping and release of the flat-panel satellite; The leveling module is communicatively connected to the sensing module and the upper-level leveling component. It is used to obtain the centroid offset of the flat-panel satellite based on the real-time pose and the pre-stored satellite centroid distribution model, and drive the upper-level leveling component to perform differential adjustment based on the centroid offset to level the flat-panel satellite to the target horizontal attitude. The overhead crane collaborative control module is communicatively connected to the sensing module and is used to plan the movement trajectory of the overhead crane based on the target stacking point information. During the movement of the overhead crane, based on the real-time pose and vibration signals provided by the sensing module, the crane vibration reduction link is driven by a predictive control algorithm to perform active vibration suppression control.

2. The flat-panel satellite adaptive stacking system according to claim 1, characterized in that, The sensing module includes a 3D LiDAR and an industrial vision camera; The real-time pose of the flat-panel satellite is generated by fusing the point cloud data from the lidar and the image data from the industrial vision camera.

3. The flat-panel satellite adaptive stacking system according to claim 2, characterized in that, The sensing module further includes: a process closed-loop unit; The process closed-loop unit is used to identify the coded identifier of the flat-panel satellite through the industrial vision camera; The encoded identifier is compared with a preset stacking sequence. If the comparison is inconsistent, or if the real-time pose is detected to exceed a preset deviation threshold, a control command is triggered to pause the stacking operation and issue an alarm. And / or, record and upload the status of key operational steps for grasping, clamping, leveling and placing the horizontal satellite.

4. The flat-panel satellite adaptive stacking system according to claim 2, characterized in that, The sensing module also includes a tilt sensor to form a real-time feedback loop; The real-time feedback loop is used to trigger the leveling control module to start the dynamic compensation process when the detected tilt angle exceeds the preset tilt angle threshold.

5. The flat-panel satellite adaptive stacking system according to claim 1, characterized in that, The leveling module employs a dynamic compensation algorithm based on robust adaptive control; The dynamic compensation algorithm combines second-order prediction and model tracking control strategies to ensure that the error of the final attitude after leveling is controlled within a certain range. Within.

6. The flat-panel satellite adaptive stacking system according to claim 1, characterized in that, The clamping module includes an internally supported gripper; The internal support claw has a flexible polymer pad on its claw surface, and a micro-motion coupling mechanism is integrated on the claw tooth contact surface to adapt to the microscopic unevenness of the flat satellite surface. The clamping module is configured to: during the clamping process, first complete the initial closure in position control mode, and then switch to force control mode to use force sensor feedback to lock the target clamping force.

7. The flat-panel satellite adaptive stacking system according to claim 6, characterized in that, The internal support gripper is also equipped with a displacement sensor; The displacement sensor is used to detect the contact distance between the claw and the flat satellite. When the contact distance is detected to be less than the preset contact distance, the crane is controlled to switch to micro-motion mode.

8. The flat-panel satellite adaptive stacking system according to claim 1, characterized in that, A dedicated wireless communication link is established between the overhead crane cooperative control module and the overhead crane. The communication latency of the dedicated wireless communication link is controlled within 50ms. The active vibration damping control is configured as follows: The amplitude is suppressed to ≤0.5° under full load conditions; Under abnormal operating conditions, switch to emergency braking mode and activate the secondary energy absorption and vibration damping device within 0.1 seconds; The abnormal operating conditions include at least one of the following: receiving an emergency stop signal from the overhead crane, detecting vibration amplitude exceeding a preset safety threshold, or sling tension exceeding a preset safety range.

9. The flat-panel satellite adaptive stacking system according to claim 1, characterized in that, The lower-level tooling components adopt a modular interface to adapt to adapters for different types of satellites.

10. A method for adaptive stacking of flat-panel satellites, characterized in that, Applied to the flat-panel satellite adaptive stacking system as described in any one of claims 1-9, the flat-panel satellite adaptive stacking method comprises: The clamping module is used to grasp the flat-panel satellite; The sensing module acquires the real-time pose and vibration signals of the clamped flat-panel satellite. The leveling module obtains the centroid offset of the flat-panel satellite based on the real-time pose and the pre-stored satellite centroid distribution model, and drives the upper-level leveling component to perform differential adjustment based on the centroid offset to level the flat-panel satellite to the target horizontal attitude. The crane collaborative control module plans the crane's movement trajectory based on the target stacking point information; and during the crane's movement, based on the real-time pose and vibration signals provided by the sensing module, the crane's vibration reduction link is driven by a predictive control algorithm to perform active vibration suppression control until the flat-panel satellite is moved to the target stacking point and placed.

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