On-Orbit Calibration Device for Space Manipulator Force Sensor
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Solution Overview
Problem
Existing calibration devices for six-dimensional force sensors on space station manipulators are unsuitable for weightless environments and are too large, making them costly and impractical for space station use.
Innovation Solution
A high-precision, miniaturized on-orbit calibration device utilizing piezoelectric ceramic plates and high-precision single-axis force sensors to generate standard loads for calibration, featuring a fixing bracket, three force applying devices, and a cubic stress block, allowing for precise calibration in a weightless environment with a compact design.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If existing calibration devices use weights for calibration, then calibration can be performed on the ground, but they cannot be used in the weightless environment of the space station
Solution Approach 1:
The patent replaces the traditional weight-based mechanical calibration system with an electromagnetic force generation system. Electromagnetic actuators generate precise forces along three orthogonal axes (X, Y, Z directions) to calibrate the six-dimensional force sensor, eliminating the need for physical weights that are ineffective in weightless environments. This substitution enables reliable calibration in space by using electromagnetic fields instead of gravitational fields.
2Measurement precision
If existing calibration devices are designed for ground use, then they provide adequate calibration precision, but they are large in size resulting in high launch cost and narrow space station constraints
Solution Approach 1:
The calibration device is segmented into three independent force applying devices, each responsible for generating forces along one of the three orthogonal axes (X, Y, or Z direction). Each device contains electromagnetic actuators and force sensors that can independently calibrate specific components of the six-dimensional force sensor. This segmentation allows the system to achieve comprehensive calibration functionality while minimizing overall device volume and mass for space deployment.
Solution Approach 2:
The calibration device is designed with multi-functionality to perform all six-dimensional calibration tasks using a compact structure. The three force applying devices can generate forces in all three spatial directions, and by combining these capabilities, the system can calibrate all six degrees of freedom (three forces and three moments) of the force sensor, replacing what would traditionally require a much larger ground-based calibration rig.
3Volume of moving object
If a compact calibration device is designed for space station, then device size is reduced, but achieving stable force source and large loads becomes difficult
Solution Approach 1:
The calibration device incorporates high-precision single-axis force sensors in each force applying device to provide real-time feedback on the generated forces. This feedback mechanism allows the control system to precisely regulate the electromagnetic actuators, ensuring stable and accurate force generation despite the compact size. The feedback loop compensates for any deviations and maintains force stability required for reliable calibration in the space environment.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
Enables accurate on-orbit calibration of six-dimensional force sensors with a stable force source, suitable for the weightless environment and the limited space of a space station, providing a cost-effective and efficient calibration method.
Implementation Method 1
utilize piezoelectric ceramic plates and high-precision one-dimensional force sensors to generate standard load
Data Source
AI summary
The present invention discloses a high-precision and miniaturized on-orbit calibration device for a six-dimensional force sensor of a space station manipulator and a calibration method thereof, which include an inverted π shape fixing bracket, three force applying devices, and a cubic stress block. Each force applying device includes a force applying head, a single axis force sensor, a force source part and a fastening part. The force source part includes an upper support plate, a second electrode plate, piezoelectric ceramic plates, a first electrode plate and a lower support plate, which are coaxially arranged sequentially from top to bottom. The single axis force sensor is mounted on the top of the upper support plate, and the hemispherical force applying head is mounted on the top of the single axis force sensor. The cubic stress block is mounted on the top of the six-dimensional force sensor.