Robotic Satellite Refuelling Valve Tool
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Solution Overview
Problem
Current technologies lack the capability to effectively refuel geosynchronous communication satellites that were not designed for robotic servicing, as they present challenges in accessing fuel systems due to design features intended for single-use fuel fill and drain valves, hindering the extension of satellite operational life.
Innovation Solution
A robotic satellite refuelling system that includes a fluid transfer system, a sensing array for precise positioning, a control system for autonomous operation, and a valve tool mechanism capable of coupling and decoupling fuel and oxidizer lines, allowing for remote and robotic refuelling of unprepared satellites.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Duration of action of moving object
If satellites are designed with single-use fuel fill and drain valves for pre-launch fueling only, then the satellite can be launched with a finite fuel load, but the satellite cannot be refuelled in orbit and must be replaced after fuel exhaustion
Solution Approach 1:
The valve tool is divided into multiple functional modules including a grapple module for securing the valve, a cutting module for removing protective covers and lockwires, a socket module for actuating the valve, and a fuel line coupling module. This segmentation allows each module to perform its specific function independently while being integrated into a single robotic-operable tool, enabling refuelling of valves originally designed for single-use pre-launch fueling only
Solution Approach 2:
A robotic valve tool serves as an intermediary between the servicing spacecraft and the satellite's fuel system. This tool mediates the complex operations of accessing, opening, and connecting to the fuel fill valve, which were originally designed for manual pre-launch operations only. The intermediary tool enables refuelling capability without modifying the original satellite design
2Reliability
If protective thermal blankets and lockwires are added to fuel valves for launch protection, then the valve is protected during launch, but the valve cannot be accessed robotically for refuelling
Solution Approach 1:
The valve tool is pre-equipped with cutting tools and removal mechanisms designed to eliminate protective thermal blankets and cut lockwires that secure the valve components. These preliminary actions of removing protective elements are built into the tool's operational sequence, allowing the robotic system to access the valve despite the protective measures originally intended to prevent manual access
Solution Approach 2:
The valve tool incorporates different functional elements at different locations to address specific protection measures: cutting tools at the front edge for removing thermal blankets, lockwire cutters positioned to access secured components, and socket mechanisms for valve actuation. Each local component is designed to overcome a specific protective feature while maintaining overall valve protection during launch
3Ease of operation
If manual operations are used to access and operate fuel valves, then the valve can be accessed and operated, but the operations cannot be performed robotically for autonomous refuelling
Solution Approach 1:
The valve tool is designed as a universal multi-functional device that can perform all operations previously requiring manual intervention: grappling the valve body, cutting protective covers and lockwires, removing and replacing valve caps, actuating the fuel fill valve, and coupling fuel lines. This multi-functionality allows a single robotic tool to replicate the entire manual valve access and operation sequence, enabling autonomous refuelling
Solution Approach 2:
The valve tool incorporates self-contained actuators and mechanisms that perform operations autonomously without continuous manual guidance. The grapple module secures itself to the valve, cutting tools automatically remove protective elements, and the socket module self-actuates the valve through mechanical engagement. This self-service capability enables full robotic automation of the refuelling process
Data Source
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AI summary
The present invention provides a method, system and apparatus for robotic refuelling of satellites. The system may include a dedicated refuelling satellite launched directly from either earth, or alternatively it could be launched from another larger mother spacecraft or space station in which the refuelling satellite is ferried into space in the case of the larger space craft or it may be stored on the space station until needed from which it can be launched. The system includes a robotic arm, suitable tools which can be affixed to the end effector of the robotic arm required for accessing, opening and closing the fuel fill valve on the satellite being serviced, storage and retrieval stations on a tool caddy on which the tools and various fuel fill valve caps are stored. The system is under teleoperation by a remotely located operator, for example located on earth, in the mother station or in the space station. Cameras are included focussed on the robotic arm and end effector and images are transmitted to the operator to allow the operator to direct and control the refuelling procedure. The system may also be configured to be operated autonomously under computer control.