Design of Modular Truss Components for On-Orbit Robotic Assembly

In recent years, on-orbit assembly has gained prominence for aerospace applications due to the escalating demand for sophisticated, large-scale space structures which cannot be launched as a whole and then deployed on-orbit. Truss structures are capable of supporting, connecting, and extending space facilities, serving as significant components of these large-scale space structures. Conventional astronaut-based assembly techniques entail substantial risks and costs, thus underscoring the need for efficient and safer alternatives. Robotic assembly has emerged as a viable solution; nevertheless, existing designs frequently cope with stringent requirements associated with on-orbit operations, including precise alignment, secure connections, and easy manipulation. This study seeks to address these challenges by introducing an innovative design of modular truss components especially tailored for on-orbit robotic assembly. A robust, highly-tolerant, and user-friendly connector system was devised to satisfy the requirements imposed by robotic manipulation and vision sensing. Secure connections were accomplished by employing a rotational tightening structure, comprising lock pins, guide grooves, and high-stiffness springs. The interface was meticulously designed to ensure compatibility with the end-effector and fiducial markers, in order to achieve reliable interaction and precise pose measurement. The assembly mechanism was conceptualized to enable facile operation by a robot and to facilitate control through vision or force sensing. Finite element analysis was employed to evaluate the mechanical properties and estimate the load capacity under relevant operating conditions. This corroboration of the design accentuates its potential for application in the construction of space structures, presenting a more efficacious and safer alternative to traditional astronaut-based assembly methods.