Periodic Reporting for period 1 - ASTROLIFT (Autonomous Spacecraft Technology for Repair Operations, Lifespan Improvement and Flight Testing)
Reporting period: 2024-02-01 to 2025-01-31
Nowadays, satellites cannot be serviced or repaired in-space. Satellites have a defined lifespan (e.g. 10-15 years for GEO telecommunication satellites) typically limited by onboard fuel and the health of different components. Based on estimations, over the last 20 years an average of 27 new GEO satellites are launched per year. Around 370 GEO satellites will reach their end of life over the 2026‐2041 period.
Launch and deployment of a single GEO satellite can cost €50-400 million and requires issuance of a license and insurance coverage, both of which are also costly. Nearing the end of life for such satellites means losing an asset for their owner or operator. Satellite owners, operators, and space agencies need viable ways to inspect and protect satellites and extend their lifetime. Moreover, it is very important to reduce the debris by managing the satellites end-of-life removing or relocating the satellite to a graveyard orbit.
D-Orbit’s GEA, a disruptive In-Orbit Servicing (IOS) spacecraft will be designed to solve the problem of expensive satellites nearing the end of their life by extending them and enabling their operators to continue generating revenues without the need to launch and deploy new satellites. GEA will be equipped with breakthrough robotics, electric propulsion, altitude and orbit control actuators (AOCS) and navigation subsystems. It will also include a capture mechanism and an advanced light detection and ranging sensor for rendezvous and proximity operations. The serviced satellite operates during most IOS procedures. GEA will be compatible with most GEO satellites currently in orbit and can extend their life up to 7 years.
IOS will complement our current logistics infrastructure and services that include orbital transportation, as well as advanced services, such as satellite-as-a-service and in-space cloud computing. As part of our technology development roadmap, we plan to provide additional IOS such as active debris removal, refueling, as well as orbital assembly and recycling over the course of the next 10 years.
Launch and deployment of a single GEO satellite can cost €50-400 million and requires issuance of a license and insurance coverage, both of which are also costly. Nearing the end of life for such satellites means losing an asset for their owner or operator. Satellite owners, operators, and space agencies need viable ways to inspect and protect satellites and extend their lifetime. Moreover, it is very important to reduce the debris by managing the satellites end-of-life removing or relocating the satellite to a graveyard orbit.
D-Orbit’s GEA, a disruptive In-Orbit Servicing (IOS) spacecraft will be designed to solve the problem of expensive satellites nearing the end of their life by extending them and enabling their operators to continue generating revenues without the need to launch and deploy new satellites. GEA will be equipped with breakthrough robotics, electric propulsion, altitude and orbit control actuators (AOCS) and navigation subsystems. It will also include a capture mechanism and an advanced light detection and ranging sensor for rendezvous and proximity operations. The serviced satellite operates during most IOS procedures. GEA will be compatible with most GEO satellites currently in orbit and can extend their life up to 7 years.
IOS will complement our current logistics infrastructure and services that include orbital transportation, as well as advanced services, such as satellite-as-a-service and in-space cloud computing. As part of our technology development roadmap, we plan to provide additional IOS such as active debris removal, refueling, as well as orbital assembly and recycling over the course of the next 10 years.
This part of the project focuses on the development of a torque-controlled robotic joint, starting from the Torque controlled robotic arm requirement definition. The project is divided into three main Work Packages:
• WP1: Torque Controlled Robotic Joint Design: This WP covers the foundational aspects of the robotic joint, including requirement analysis, design, and analysis of key components.
• WP2: Torque Controlled Robotic Joint Procurement & Manufacturing & Testing: This WP encompasses the practical implementation of the joint design, including procurement of necessary components, manufacturing processes, and rigorous testing procedures.
• WP3: Torque Controlled Robotic Arm Design (no SW): This WP focuses on the overall robotic arm requirement definition. Starting from these requirements, the robotic joint requirements has been derived
• WP4: Communication and IP Management: This WP deals with dissemination, exploitation and communication about activities developed in ASTROLIFT, as well as generated IP management and protection
Completed Activities:
During this initial project phase, a document-based approach was employed to define the requirements for the robotic arm and its joints. In the subsequent phase (WP1.5) we will transition to a Model-Based Systems Engineering (MBSE) approach for system engineering activities.
• WP1.1 Requirement, Specification and Architectural Design (Completed): Starting from the robotic arm requirements, comprehensive requirements and specifications for the torque-controlled robotic joint have been meticulously defined, laying a solid foundation for subsequent design and development activities. A robust architectural design has been established, outlining the overall system structure and the interconnections between various components.
• WP1.2 Joint Mechanical Design and Analysis: the detailed mechanical design of the breadboard model version of the robotic joint is ongoing. This involves detailed analysis and optimization of critical mechanical components to enhance performance, durability, and efficiency.
• WP1.3 Torque Sensor Design and Analysis: as for the mechanical components, the breadboard model version of the torque sensor development is ongoing. Continuous improvements are being made to the design and analysis of the torque sensor. This includes exploring innovative sensor technologies, optimizing sensor placement and integration, and conducting rigorous simulations to ensure accurate and reliable torque measurements.
• WP1.4 Electronics, Firmware and control Software Design: for the breadboard model version, we concentrate in the development of the robotic joint control strategies development, analysis and simulation, to be ready for the physical model tests to be completed in the next project phases. To speed up the joint development, in the breadboard model version, we decided to select Component Off The Shelf (COTS) for electronics and low level software/firmware. In the next project phases, a custom electronic will be developed
• WP1.5 System Analysis and Documentation: the transition from documental approach to Model Based System Engineering (MBSE) approach is started. All the joint and arm requirement have been imported in the dedicated software (Enterprise Architect) together with functional and physical architecture. This approach improves maintainability of the model, enable the automatic generation (and updates) of the documents and reduces the effort of the system engineering activities.
• WP2.1 Procurement, Manufacturing and testing of BBM: The procurement of the BBM component is currently ongoing. In the next project phases, the BBM will be manufactured and then tested. To mitigate procurement lead times, also the laboratory equipment needed to perform the test has been purchased proactively during the last quarter of 2024. Moreover, to mitigate manufacturing lead time, starting from the preliminary Robotic Joint design the manufacturing team is performing the feasibility analysis, and they are evaluating the most suitable production technique for the BBM manufacturing
• WP3.1 Robotic Arm Requirement and Specification: preliminary requirements and specifications for the entire robotic arm system have been finalized. These preliminary specifications guide the design and development of the robotic joint, ensuring it meets the desired performance criteria and operational needs.
Ongoing Activities:• WP4.1 Dissemination and communication: the dissemination and communication plan has been completed and the communication actions are being implemented, with attendance to strategic conferences
• WP1: Torque Controlled Robotic Joint Design: This WP covers the foundational aspects of the robotic joint, including requirement analysis, design, and analysis of key components.
• WP2: Torque Controlled Robotic Joint Procurement & Manufacturing & Testing: This WP encompasses the practical implementation of the joint design, including procurement of necessary components, manufacturing processes, and rigorous testing procedures.
• WP3: Torque Controlled Robotic Arm Design (no SW): This WP focuses on the overall robotic arm requirement definition. Starting from these requirements, the robotic joint requirements has been derived
• WP4: Communication and IP Management: This WP deals with dissemination, exploitation and communication about activities developed in ASTROLIFT, as well as generated IP management and protection
Completed Activities:
During this initial project phase, a document-based approach was employed to define the requirements for the robotic arm and its joints. In the subsequent phase (WP1.5) we will transition to a Model-Based Systems Engineering (MBSE) approach for system engineering activities.
• WP1.1 Requirement, Specification and Architectural Design (Completed): Starting from the robotic arm requirements, comprehensive requirements and specifications for the torque-controlled robotic joint have been meticulously defined, laying a solid foundation for subsequent design and development activities. A robust architectural design has been established, outlining the overall system structure and the interconnections between various components.
• WP1.2 Joint Mechanical Design and Analysis: the detailed mechanical design of the breadboard model version of the robotic joint is ongoing. This involves detailed analysis and optimization of critical mechanical components to enhance performance, durability, and efficiency.
• WP1.3 Torque Sensor Design and Analysis: as for the mechanical components, the breadboard model version of the torque sensor development is ongoing. Continuous improvements are being made to the design and analysis of the torque sensor. This includes exploring innovative sensor technologies, optimizing sensor placement and integration, and conducting rigorous simulations to ensure accurate and reliable torque measurements.
• WP1.4 Electronics, Firmware and control Software Design: for the breadboard model version, we concentrate in the development of the robotic joint control strategies development, analysis and simulation, to be ready for the physical model tests to be completed in the next project phases. To speed up the joint development, in the breadboard model version, we decided to select Component Off The Shelf (COTS) for electronics and low level software/firmware. In the next project phases, a custom electronic will be developed
• WP1.5 System Analysis and Documentation: the transition from documental approach to Model Based System Engineering (MBSE) approach is started. All the joint and arm requirement have been imported in the dedicated software (Enterprise Architect) together with functional and physical architecture. This approach improves maintainability of the model, enable the automatic generation (and updates) of the documents and reduces the effort of the system engineering activities.
• WP2.1 Procurement, Manufacturing and testing of BBM: The procurement of the BBM component is currently ongoing. In the next project phases, the BBM will be manufactured and then tested. To mitigate procurement lead times, also the laboratory equipment needed to perform the test has been purchased proactively during the last quarter of 2024. Moreover, to mitigate manufacturing lead time, starting from the preliminary Robotic Joint design the manufacturing team is performing the feasibility analysis, and they are evaluating the most suitable production technique for the BBM manufacturing
• WP3.1 Robotic Arm Requirement and Specification: preliminary requirements and specifications for the entire robotic arm system have been finalized. These preliminary specifications guide the design and development of the robotic joint, ensuring it meets the desired performance criteria and operational needs.
Ongoing Activities:• WP4.1 Dissemination and communication: the dissemination and communication plan has been completed and the communication actions are being implemented, with attendance to strategic conferences
The successful development of this torque-controlled robotic arm has the potential to revolutionize IOS applications by enabling a lot of services such as visual inspection, i.e. rendezvous and imaging with a satellite, satellite lifetime extension by providing propulsion/actuation capabilities, relocation of a satellite on a different orbit and end-of-life management, i.e. removal or relocation of a satellite to a graveyard orbit.
These services will contribute to mitigate the debris management problem and extend the satellites life up to 7 years.
These services will contribute to mitigate the debris management problem and extend the satellites life up to 7 years.