Software for the SpaceDREAM Robotic Arm

Impedance-controlled robots are widely used on Earth to perform interaction-rich tasks and will be a key enabler for In-Space Servicing, Assembly and Manufacturing (ISAM) activities. This paper introduces the software architecture used on the On-Board Computer (OBC) for the planned SpaceDREAM mission aiming to validate such robotic arm in Lower Earth Orbit (LEO) conducted by the German Aerospace Center (DLR) in cooperation with KINETIK Space GmbH and the Technical University of Munich (TUM). During the mission several free motion as well as contact tasks are to be performed in order to verify proper functionality of the robot in position and impedance control on joint level as well as in cartesian control. The tasks are selected to be representative for subsequent servicing missions e.g. requiring interface docking or precise manipulation. The software on the OBC commands the robot's joints via SpaceWire to perform those mission tasks, reads camera images and data from additional sensors and sends telemetry data through an Ethernet link via the spacecraft down to Earth. It is set up to execute a predefined mission after receiving a start signal from the spacecraft while it should be extendable to receive commands from Earth for later missions. Core design principle was to reuse as much existing software and to stay as close as possible to existing robot software stacks at DLR. This allowed for a quick full operational start of the robot arm compared to a custom development of all robot software, a lower entry barrier for software developers as well as a reuse of existing libraries. While not every line of code can be tested with this design, most of the software has already proven its functionality through daily execution on multiple robot systems.

AI-enabled Cyber-Physical In-Orbit Factory -- AI approaches based on digital twin technology for robotic small satellite production

With the ever increasing number of active satellites in space, the rising demand for larger formations of small satellites and the commercialization of the space industry (so-called New Space), the realization of manufacturing processes in orbit comes closer to reality. Reducing launch costs and risks, allowing for faster on-demand deployment of individually configured satellites as well as the prospect for possible on-orbit servicing for satellites makes the idea of realizing an in-orbit factory promising. In this paper, we present a novel approach to an in-orbit factory of small satellites covering a digital process twin, AI-based fault detection, and teleoperated robot-control, which are being researched as part of the "AI-enabled Cyber-Physical In-Orbit Factory" project. In addition to the integration of modern automation and Industry 4.0 production approaches, the question of how artificial intelligence (AI) and learning approaches can be used to make the production process more robust, fault-tolerant and autonomous is addressed. This lays the foundation for a later realisation of satellite production in space in the form of an in-orbit factory. Central aspect is the development of a robotic AIT (Assembly, Integration and Testing) system where a small satellite could be assembled by a manipulator robot from modular subsystems. Approaches developed to improving this production process with AI include employing neural networks for optical and electrical fault detection of components. Force sensitive measuring and motion training helps to deal with uncertainties and tolerances during assembly. An AI-guided teleoperated control of the robot arm allows for human intervention while a Digital Process Twin represents process data and provides supervision during the whole production process. Approaches and results towards automated satellite production are presented in detail.