Design Characteristics Computing of a Robotic Platform for the Spacecraft Structures Elements Manufacturing and Refurbishment under the Orbital Flight Conditions

Aeronautical and Space-Rocket Engineering


Аuthors

Ashimov I. N.

S. P. Korolev Rocket and Space Corporation «Energia», 4A Lenin Street, Korolev, Moscow area, 141070, Russia

e-mail: ilyas.ashimov@rsce.ru

Abstract

Development and manufacturing of the new equipment meeting the operation conditions in the outer space is urgent for ensuring the possibility of products operative manufacturing or repairing. A robotic platform with integrated wire electric arc additive technology is one of the options for such installation.
Several tasks have been defined for the design characteristics computing of the platform:
1. Developing mathematical models for the kinematic and dynamic characteristics computing of a multi-link manipulator with account for the outer space impact.
2. Performing numerical modeling of the installation to assess the strength characteristics while launching into orbit and operation as a part of the orbital station.
3. Developing the structure and means for products additive manufacturing and repairing at the orbital station.
With account for the initial data on the maximum overall dimensions of the elements, as well as operating conditions, requirements for the strength and reliability of the structure, etc., the authors performed an analysis of several types of the equipment. Based on the results of the analysis, the most preferable option is a robotic complex (RC), since it satisfies the overall dimensions and weight requirements, possesses wider capabilities in the products manufacturing and repairing, as well as there is certain experience in operating multi-link manipulators on orbital stations.
On the assumption of the specified requirements, a 3D-model of the installation (as a part of the RTC) was developed in the “PTC Creo 7.0” CAD system, based on typical design solutions for industrial arc welding robots (Kuka, Fanuc, Hanwha). The robot is a manipulator with six degrees of freedom with the rotational type of joints, which relative position of is being determined by an angular variable.
To determine both geometric and inertial parameters of the links, mathematical modeling of the manipulator was performed in the MathCAD 15.0 software with its kinematic and dynamic schemes concretization. Simulation results include the graphs of actuating device linear and angular velocities dependence, as well as the graphs of the dependencies of generalized forces and moments.
To assess the strength properties of the developed manipulator structure, numerical modeling with the finite element method in the ANSYS software package was performed. The objective of the numerical modeling consisted in determining the level of stresses and displacements of the structure under static, dynamic and thermal loads in the most dangerous loading cases, namely when launching the product into orbit and during operation as a part of the orbital station. It was found by the results of static, dynamic and thermostatic analysis that the resulting stresses did not lead to irreversible deformation of the structure. However, when operating the product in the process of additive surfacing, forced movements might lead to a significant deviation from the specified trajectory of the actuating element.
As the result of mathematical and numerical modeling, a 3D-model of the printing platform, consisting of an arc additive surfacing robot, a robotic manipulator, a work table, assembly units, power supply and thermal control systems, was developed.

Keywords:

robotic platform, electric arc additive technology, 3D-printing in space, space manipulator, structures refurbishment on the space station

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