Robotically Controlled Satellite Refueling Tool
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Solution Overview
Problem
Current technologies lack the capability to effectively and safely access and manipulate propellant fill/drain valves on unprepared artificial satellites for on-orbit propellant resupply operations, due to design challenges and safety concerns with corrosive and explosive propellants, and existing tools are not adaptable to various valve designs and orientations.
Innovation Solution
A suite of supporting tools with vision-based and sensor-based feedback mechanisms, including a common tool base and adaptable mechanisms, is developed to facilitate on-orbit refueling of satellites with quick connect safety valves, enabling robotic access and manipulation of propellant valves through a robotic arm, accommodating various valve designs and orientations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If robotic tools are used to access and manipulate propellant fill/drain valves on unprepared satellites, then on-orbit propellant resupply capability is achieved, but the complexity of the tool system increases significantly due to the need to accommodate various valve designs and orientations
Solution Approach 1:
The refueling tool incorporates a universal interface system that can accommodate multiple valve designs and orientations through interchangeable adapters and a standardized mounting mechanism. The tool base includes a multi-axis positioning system with adjustable grippers that can interface with different valve configurations, allowing a single tool to perform multiple functions across various satellite types without requiring satellite-specific tooling.
Solution Approach 2:
The tool employs dynamic positioning and adjustment mechanisms including articulated arms with multiple degrees of freedom, adjustable gripper forces, and real-time orientation sensing. These dynamic elements allow the tool to adapt its configuration during operation to match the specific valve geometry and orientation, providing versatility without requiring multiple fixed-purpose tools.
2Reliability
If precise control and alignment mechanisms are added to ensure successful engagement with satellite valves, then operational reliability improves, but the device complexity and manufacturing difficulty increase
Solution Approach 1:
The refueling tool integrates vision-based alignment systems with sensors that detect valve position, orientation, and geometry in real-time. The control system processes this feedback data to automatically adjust tool positioning and gripper configuration, ensuring precise engagement with the target valve. This closed-loop control significantly improves reliability by compensating for positioning errors and accommodating manufacturing tolerances.
Solution Approach 2:
The tool incorporates preliminary alignment features including approach path guidance, pre-engagement positioning mechanisms, and automated valve identification routines. These preliminary actions prepare the tool for accurate engagement before the critical connection phase, reducing the risk of failed attempts and improving overall operational reliability.
3Adaptability or versatility
If a suite of specialized tools is developed to handle different valve types, then the ability to service diverse satellites improves, but the time required for tool preparation and operation increases
Solution Approach 1:
The tool system is segmented into modular components including a standardized base unit and interchangeable specialized attachments for different valve types. This segmentation allows the core tool to remain simple while enabling rapid adaptation through module swaps. The modular architecture reduces preparation time compared to reconfiguring a single complex tool, as pre-built modules can be quickly exchanged based on the target satellite's valve configuration.
Solution Approach 2:
The tool incorporates scanning and measurement capabilities that create digital models of the target valve geometry. These copied geometric data are used to automatically generate engagement parameters and control sequences, eliminating the need for manual programming for each valve type. This virtual copying approach accelerates the adaptation process while maintaining high precision.
Data Source
Figure 1
Figure 1A~1B
Figure 1C~1D
AI summary
The present disclosure relates to a robotically controlled satellite refueling tool and associated robotically controlled support and site preparation tools which facilitates on-orbit refueling by teleoperation of fill/drain valves of various designs and dimensions on satellites not originally prepared for on-orbit servicing, through the installation of quick connect safety valves, using vision-based feedback as well as feedback from sensors embedded in the refueling tool to operate a suite of adaptable and adjustable mechanisms. The refueling tool has an open architecture to allow a refueling tool vision system to see the fill/drain valve and the section of the refueling tool that is engaged with the fill/drain valve. The support tools include a blanket cutter tool (605, Fig. 32), a blanket handler tool (606, Fig. 33), a wire cutter tool (607, Fig. 34), a gripper tool, and the site preparation tools include a B-nut removal tool (608, Fig. 35) and a crush seal removal tool (609, Fig. 36). Each of these tools includes a common base structure (603, Fig. 30) which is interfaced to the end effector of the robotic arm for transmitting rotation and torque to the various tools.