Space Factory 4.0 - New processes for the robotic assembly of modular satellites on an in-orbit platform based on „Industrie 4.0� approach

Manufacturing in Space is fast becoming a reality, with the commercialisation of space operations - the so-called NewSpace - leading to a sea-change in the space industry and the emergence of new business models. Inspired by the new opportunities related to NewSpace, the project Space Factory 4.0 has been founded with the objective of establishing new processes and technologies for rapid satellite assembly on an in-orbit platform. To make a significant step towards reaching this visionary goal, this paper discusses: (i) the establishment of new processes for manufacturing in space based on an Industrie 4.0 approach, (ii) the design of highly modular satellites, and (iii) their robotic assembly. The objectives of Industrie 4.0 are to enable flexibility, modularity, and adaptability of production systems by exploiting the capabilities of Cyber-Physical Systems. Based on Industrie 4.0 principles, an overall process for Space Factory 4.0 is proposed. Although the specific case of robotic assembly of modular satellites is focused, this approach is applied to abstract new business models. One of the key features of the overall process is the seamless use of the Digital Twin approach which provides detailed models representing the actual state of a physical component or system. Use-cases such as automated testing and digital product documentation are described to illustrate the benefits of such technology. Implementing fast development cycles and modern manufacturing concepts can avail of modular systems that enable automated integration and verification processes. Space Factory 4.0 aims at establishing a highly modular design for small satellites that increases efficiency and scalability during production and testing. Based on this design, automated integration and verification of small satellites will be demonstrated to prepare for a future in-orbit factory. Although autonomous integration and assembly in space are the long-term goals, currently the technology for visual tracking and for modelling the physical interaction between the satellite components, the platform and the robotic manipulators is not always perfectly reliable. As an alternative solution, Space Factory 4.0 aims at developing a bilateral controller which allows for teleoperation of the assembly robot by a human operator using a Human-Machine-Interface (HMI), providing force feedback with the support of virtual fixtures. The paper discusses a concept of such a haptic telerobotic system, which aims at combining the capabilities of robots for operating in remote environments with the human's intelligence. This paper outlines the methods and the results obtained within Space Factory 4.0 and draws conclusions to discuss its benefits and potentials for the space industry.