Nested Tool Drive System with Universal Actuator
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Solution Overview
Problem
Existing tool drive systems for robotic servicing in space, such as low earth orbit (LEO) and geosynchronous earth orbit (GEO), face challenges due to harsh environmental conditions like extreme temperatures and radiation, which affect the reliability and efficiency of brushless direct current (BLDC) motors and gearmotors. Additionally, the need for multiple actuators with varying stall torque and speed capabilities complicates system design and increases costs.
Innovation Solution
The Advanced Tool Drive System (ATDS) incorporates four brushless direct current (BLDC) motors with a common gearhead design and a camera positioning mechanism. It features a unique tool drive interface with a kinematic mount design, allowing for the attachment and actuation of various tools through a common interface, and includes a ball-lock coupler system for efficient coupling and decoupling of tools.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If multiple actuators with different stall torque and speed capabilities are used, then the system can meet varying performance requirements for different tools, but the device complexity and cost increase
Solution Approach 1:
The patent implements a universal actuator design where a single BLDC motor with gearhead can serve multiple tool interfaces (202, 204, 206) with different torque and speed requirements. The actuator achieves this through variable gear ratios in the gearhead mechanism, allowing one actuator to replace what would traditionally require multiple specialized actuators, thereby reducing system complexity while maintaining adaptability to various tool performance needs
2Adaptability or versatility
If multiple actuators with different capabilities are used, then various tool performance requirements can be met, but the cost increases
Solution Approach 1:
The patent reduces manufacturing cost by consolidating multiple specialized actuators into a single universal actuator design. The common gearhead with variable gear ratios allows one actuator to interface with multiple tool types (202, 204, 206), eliminating the need to manufacture, stock, and maintain multiple different actuator models, thereby reducing overall system cost while maintaining full tool interface compatibility
3Weight of moving object
If the overall size and mass of the ATDS are limited, then the robotic system meets operational constraints, but packaging the motors and maintaining torque margins becomes more challenging
Solution Approach 1:
The patent employs a nested arrangement where the tool interfaces (202, 204, 206) are positioned concentrically around the single BLDC motor with gearhead. This nested configuration allows multiple tool mounting positions to be achieved within a compact radial footprint, efficiently utilizing the limited space while maintaining the necessary torque transmission paths and mechanical clearances, thus reducing overall ATDS mass and simplifying packaging
Data Source
AI summary
An advanced tool drive system (ATDS) is capable of grasping a variety of tools through a common interface and provides multiple modes of operation for these tools for these tools. The ATDS is a combination of both a tool actuator and tool change-out mechanism and provides three nested drive actuators-two rotary and one linear. In addition to the tool drive, the ATDS includes four brushless direct current (BLDC) motors which provide the actuation torque to accomplish the multiple modes of ATDS operation, and a camera positioning mechanism (CPM) capable of viewing features on a client satellite or asteroid. By consolidating the drive actuation motors within the ATDS, the design of mating tools becomes less complex and reduces risk and cost of multiple drive actuators having to be installed in multiple tools.