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

In-Space Servicing, Assembly, and Manufacturing (ISAM) is a set of emerging operations that provides several benefits to improve the longevity, capacity, mobility, and expandability of existing and future space assets. Serial robotic manipulators 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 additional study. While many dynamical models are developed, experimentally testing 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, enabling 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. This is the author's original manuscript (pre-print) of the paper AAS 25-426, presented at the 35th AAS/AIAA Space Flight Mechanics Meeting, Kaua'i, Hawaii, January 19-23, 2025.INTRODUCTION The emerging capabilities offered by In-Space Servicing, Assembly, and Manufacturing (ISAM) can vastly expand the ranges of operation for in-space assets to improve reusability, mobility, ex-pandability, sustainability, and mission lifespans. ISAM operations permit servicing of existing satellites, repurposing and recycling of satellites, manufacturing and construction in-orbit, refueling, and upgrades to existing satellites.