Advancing research and development of Large Space Structures

Research is being carried out by a team at the Munich University of Applied Sciences, Germany, on the behaviour of photopolymer adhesives for in-situ repair and maintenance in space. Photopolymer adhesives can be applied in liquid and cured with UV light, creating strong bonds that will help mend cracks, apply patches, reinforce joints and even assemble LSSs.

SpaceAlign is a project being developed by the Danish Technological Institute, developing robotics for the construction, maintenance and recycling of LSS. It is centred around four main objectives:

developing robotic self-adaptation techniques for modular LSS assembly and disassembly;

integrating trustworthiness checkers and runtime verification to ensure operational resilience;

promoting sustainable recycling of LSS components;

engaging stakeholders through open-access simulations.

The Lunar Gateway is a good use case example of this study, in which robotics can autonomously assemble the Gateway from modular components, manage solar power arrays and facilitate its eventual decommissioning.

A team from Northumbria University (UK) is studying how to measure the dynamic properties of LSS at various assembly stages. This approach permits the prediction of final dynamic properties of the fully assembled structure, detect any deviations from the pre-set design properties, and find mitigations during assembly to ensure the final structure matches the design specifications.

Researchers at the University of Trieste are investigating the feasibility of LSS assembly via a modular framework designed for robotic integration. Central to this architecture is a structure-traversing robot that utilises integrated rails on the modular components for locomotion and assembly. The components will also include embedded sensors and house the electrical distribution system, providing power and data throughout the structure.

The components will consist of links and nodes which will be connected via built-in structural/electrical connectors. Additional connectors will be placed along the structure, which will provide mechanical and electrical connection to functional modules as in habitats, battery modules or scientific equipment.

SKYWALKER is a project being developed by Aalborg University in Denmark, in which autonomous robotic locomotion is being investigated within the LSS environment. Using deep reinforcement learning, the robotic arm will adaptively plan and execute multi-step movements through trial-and-error learning, handling unpredictable conditions, complex structures, and dynamic environments without extensive modelling. Ultimately, this adaptable robotic navigation system will significantly reduce the need for human intervention in space operations.

EARLY TECHNOLOGY DEVELOPMENT

LOFT is a project led by UK based company Satellite Applications Catapult, which will develop advanced design and engineering technologies within a comprehensive structural geometry and analysis framework for robotically assembled LSS. The project uses a loose-fit design system: a multi-scale, multi-fidelity digital workflow that explores component geometry and assembly logics, facilitating the design of various types of LSS. The workflow will also integrate design-for-reuse strategies to address logistics and decommissioning.

The OSTAR-RL project employs Reinforcement Learning to derive optimal assembly trajectories based on a multi-variable constraint set. This framework accounts for both structural design parameters and robotic system limitations (e.g. power margins and docking interfaces) to facilitate fully autonomous, end-to-end LSS assembly. The ultimate goal of the OSTAR-RL project is to demonstrate how autonomous systems can minimise human input into complex assembly sequences whilst providing an efficient and safe operating process.

The Intelligent Space Ethernet Time Sensitive Network (TSN) Interfaces Aggregator is a device that will gather traffic from multiple devices of different interface technologies and protocols, such as control signals, avionics, health-status and monitoring cameras. Being developed by ITTI, Poland, the proposed device will have additional functions like data processing and network monitoring. It will allow rapid validation of robotic setups without costly re-engineering of several device interfaces during ground tests. It will also bring necessary flexibility for the TNS network deployed on LEO during Large Space Structures assembly.

The feasibility of passive shearography inspection and the development of a concept prototype for ground laboratory tests is being evaluated by a team at TU DELFT. Sherography is a non-destructive testing method that detects microstrain-level surface irregularities induced by external excitations such as heat or vibration, captured by cameras under laser illumination. It allows for the identification of small yet critical defects, including closed cracks and kissing bonds.

Prior to the start of the project, the team had already extended the application of shearography to detecting sub-millimetre and deep defects and inspecting curved geometries, which are capabilities often beyond commercial instruments. ShearScope aims to build on these advances, contributing to more reliable, energy-efficient, and autonomous on-orbit inspection of space structures.

CO-SPONSORED RESEARCH

ECHO2 is being developed by a team from the University of Malaga. The research is focused on end-to-end visuomotor pipeline that assists robotic systems to autonomously inspect, diagnose, and repair diverse components, regardless of their shape or orientation, without markers or standardised interfaces. To validate this technology, the team will demonstrate robotic inspection and repair tasks on a scaled-down mock-up of an LSS on a free-floating testbed. A robotic arm will autonomously inspect, diagnose, and, as necessary, plan a course of action to repair components of varying sizes and shapes, demonstrating the robot’s ability to execute complex, long-horizon tasks without human intervention.

At ISAE-SUPAERO in France, a team is developing an end-to-end in-orbit assembly scenario of a large antenna. By using modelling and control of large flexible structures and antenna technology, the project will focus on:

Manufacturing and assembly of a large lightweight antenna structure

Design an Attitude and Orbital Control algorithm that takes into account all gravitational, thermal, radiation, structural flexibility (including fuel sloshing effects) when assembling the antenna and which adapts accordingly to the variation of the spacecraft inertia

Propose a set of actuators and sensor to assure the alignment of each assembled module and to actively mitigate vibration after assembly

Propose an innovative in-situ identification of the antenna structure by directly using the diagnostic of the radio-frequency received/transmitted signal.

A team from the Cranfield University (UK) is developing adaptable stackable tiles that provide both structural integrity to the LSS and a means for robotic locomotion to assembly robots. Each adaptable tile can accommodate several payloads, from mirrors to solar panels, and includes a built-in rail system. This rail allows assembly robots to move efficiently along the structure without additional support elements, reducing complexity and enhancing the robustness of the robotic operations. Integrated interfaces in the tiles ensure electrical, data, and mechanical connectivity across units, minimising robotic operations for harnessing and assembly. This modular system enables rapid, cost-effective LSS assembly, with tiles that can be reconfigured or expanded to meet mission needs.

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