Modular Aerial Robot Systems (MARS) consist of multiple drone modules that are physically bound together to form a single structure for flight. Exploiting structural redundancy, MARS can be reconfigured into different formations to mitigate unit or rotor failures and maintain stable flight. Prior work on MARS self-reconfiguration has solely focused on maximizing controllability margins to tolerate a single rotor or unit fault for rectangular-shaped MARS. We propose TransforMARS, a general fault-tolerant reconfiguration framework that transforms arbitrarily shaped MARS under multiple rotor and unit faults while ensuring continuous in-air stability. Specifically, we develop algorithms to first identify and construct minimum controllable assemblies containing faulty units. We then plan feasible disassembly-assembly sequences to transport MARS units or subassemblies to form target configuration. Our approach enables more flexible and practical feasible reconfiguration. We validate TransforMARS in challenging arbitrarily shaped MARS configurations, demonstrating substantial improvements over prior works in both the capacity of handling diverse configurations and the number of faults tolerated. The videos and source code of this work are available at the anonymous repository: https://anonymous.4open.science/r/TransforMARS-1030/

Modular Aerial Robotic Systems (MARS) consist of multiple drone units that can self-reconfigure to adapt to various mission requirements and fault conditions. However, existing fault-tolerant control methods exhibit significant oscillations during docking and separation, impacting system stability. To address this issue, we propose a novel fault-tolerant control reallocation method that adapts to arbitrary number of modular robots and their assembly formations. The algorithm redistributes the expected collective force and torque required for MARS to individual unit according to their moment arm relative to the center of MARS mass. Furthermore, We propose an agile trajectory planning method for MARS of arbitrary configurations, which is collision-avoiding and dynamically feasible. Our work represents the first comprehensive approach to enable fault-tolerant and collision avoidance flight for MARS. We validate our method through extensive simulations, demonstrating improved fault tolerance, enhanced trajectory tracking accuracy, and greater robustness in cluttered environments. The videos and source code of this work are available at https://github.com/RuiHuangNUS/MARS-FTCC/

Abstract-- Modular Aerial Robotic Systems (MARS) consist of multiple drone units assembled into a single, integrated rigid flying platform. With inherent redundancy, MARS can selfreconfigure into different configurations to mitigate rotor or unit failures and maintain stable flight. However, existing works on MARS self-reconfiguration often overlook the practical controllability of intermediate structures formed during the reassembly process, which limits their applicability. In this paper, we address this gap by considering the control-constrained dynamic model of MARS and proposing a robust and efficient self-reconstruction algorithm that maximizes the controllability margin at each intermediate stage. Specifically, we develop algorithms to compute optimal, controllable disassembly and assembly sequences, enabling robust self-reconfiguration. Finally, we validate our method in several challenging fault-tolerant self-reconfiguration scenarios, demonstrating significant improvements in both controllability and trajectory tracking while reducing the number of assembly steps.