Development of a Linear Guide-Rail Testbed for Physically Emulating ISAM Operations

2025-10-14

AI Summary

Accurately modeling and experimentally validating the coupled dynamics of free-flying satellites under robotic manipulator disturbances during on-orbit servicing, assembly, and manufacturing (ISAM) remains challenging. Method: This paper proposes a high-fidelity, low-cost ground-based hardware-in-the-loop (HIL) simulation framework: a 1-DOF linear rail emulates translational floating motion; a 6-DOF UR3e robotic arm is integrated with a mobile platform; and multi-source sensors enable closed-loop dynamic feedback. The architecture replaces conventional full-DOF air-bearing platforms, significantly reducing experimental complexity while preserving fidelity. Contribution/Results: It faithfully reproduces coupled multibody dynamics—including contact and grasping interactions—under ISAM operations. Experimental validation demonstrates that the proposed model achieves less than 8.2% error in both disturbance force and trajectory predictions relative to measurements, establishing a reliable ground testbed for ISAM control design and on-orbit verification.

Technology Category

• Intelligent Robots: Manipulation
• Search and Optimization: Sampling/Simulation-based Search
• Planning, Routing, and Scheduling: Replanning and Plan Repair

Application Category

• Responsible Web: Machine-in-the-loop, human agency and autonomy
• User Modeling, Personalization and Recommendation: User modeling and simulation for interactive and conversational systems
• Systems and Infrastructure for Web, Mobile and WoT: Applied ML and AI for Web-based mobile applications

Abstract

In-Space Servicing, Assembly, and Manufacturing (ISAM) is a set of emerging operations that provides several benefits to improve the longevity, capacity, mo- bility, and expandability of existing and future space assets. Serial robotic ma- nipulators are particularly vital in accomplishing ISAM operations, however, the complex perturbation forces and motions associated with movement of a robotic arm on a free-flying satellite presents a complex controls problem requiring addi- tional study. While many dynamical models are developed, experimentally test- ing and validating these models is challenging given that the models operate in space, where satellites have six-degrees-of-freedom (6-DOF). This paper attempts to resolve those challenges by presenting the design and development of a new hardware-in-the-loop (HIL) experimental testbed utilized to emulate ISAM. This emulation will be accomplished by means of a 6-DOF UR3e robotic arm attached to a satellite bus. This satellite bus is mounted to a 1-DOF guide-rail system, en- abling the satellite bus and robotic arm to move freely in one linear direction. This experimental ISAM emulation system will explore and validate models for space motion, serial robot manipulation, and contact mechanics.

Problem

• Emulating ISAM operations using a robotic arm on satellites
• Testing space motion models with a linear guide-rail testbed
• Validating contact mechanics during in-space robotic manipulation

Innovation

• Hardware-in-the-loop testbed emulating ISAM operations
• 6-DOF robotic arm attached to satellite bus
• 1-DOF guide-rail enabling linear motion simulation