Session: 06-01-01: General Aerospace-1

Paper Number: 164984

Inspection and Fault Detection Process Using a 3D Scanner for an On-Orbit Spacecraft 

In-Space Servicing, Assembly, and Manufacturing (ISAM) is an emerging technology designed to transform space exploration by enabling in-orbit operations such as spacecraft repair, upgrading, refueling, and manufacturing. This technology represents a major shift from traditional spacecraft deployment, offering enhanced flexibility, adaptability, and sustainability in space missions. The significance of ISAM technologies lies in their ability to extend the lifespan of satellites, reduce costs associated with launching new spacecraft, and facilitate the construction of complex space structures. Furthermore, ISAM addresses critical challenges in on-orbit maintenance, empowering spacecraft to undergo repairs and upgrades, which strengthens mission resilience and ensures the long-term viability of space infrastructure. Moreover, ISAM can help reduce space debris by minimizing the need for continuous satellite replacement launches, thus decreasing the generation of debris in Earth's orbit. As human presence in space increases, ISAM becomes a key enabler for advancing satellite deployment, construction, and maintenance, unlocking new possibilities for space exploration.

This study introduces an innovative methodology and proof of concept for three-dimensional (3D) inspection and fault detection of on-orbit spacecraft. The approach utilizes a collaborative robot (cobot) arm integrated with a 3D scanner, with a human-machine interface (HMI) incorporated into the system design. The cobot arm is used to navigate the 3D scanner across the external surface of a spacecraft hull, ensuring thorough inspection coverage within predefined parameters. The HMI facilitates efficient interaction between the human operator and the robotic system, optimizing the inspection process. This combination of advanced robotics and HMI represents a holistic approach to inspecting and detecting faults in spacecraft, offering an effective solution to this complex task.

The proof of concept was demonstrated using a model spacecraft hull, where the cobot's movements followed an optimized scanning pattern designed through a series of tests to achieve the most effective scan. The hull was scanned both before and after simulating damage, and the resulting 3D scanner-generated Computer-Aided Design (CAD) files were analyzed to identify faults. This analysis was carried out using MeshLab, an open-source software, where the CAD files of the undamaged and damaged hulls were compared to detect any discrepancies. MeshLab’s comparison function proved instrumental in fault detection, allowing for a detailed analysis of the differences between the undamaged and damaged models.

To further demonstrate the capabilities of the method, the study involved scanning a hull model exhibiting severe deformation. The scanned model was compared with the undeformed version using MeshLab, and the results were visualized through a heat map, highlighting surface anomalies in different colors. This heat map effectively illustrated the software’s ability to detect and quantify damages on the spacecraft hull model, providing a clear assessment of the extent and distribution of the damage. The method's efficiency and practicality were validated, showcasing its potential for real-world applications in spacecraft maintenance and repair.

Upon identifying a fault, a decision-making process is implemented based on a Finite Element Analysis (FEA) of the damaged component. This analysis categorizes the severity of the damage, determining whether immediate repair, future repair, or no repair is necessary. The forthcoming full paper will provide a comprehensive explanation of the methodology, including the FEA process, and will present three case studies addressing different scenarios of damage severity. These case studies will offer valuable insights into the decision-making process for managing faults in on-orbit spacecraft.

In summary, this study proposes a promising approach to enhancing the capabilities of spacecraft inspection and fault detection. By combining advanced robotics, 3D scanning technology, and FEA analysis, this methodology contributes to maintaining the integrity and functionality of spacecraft, supporting the long-term sustainability of space exploration efforts. The forthcoming paper will provide further details on the methodology and present real-world case studies that highlight its potential applications in the growing field of ISAM.

Presenting Author: Kayla Dremann University of Akron

Presenting Author Biography: Kayla Dremann is a graduate researcher at the University of Akron, specializing in the in-situ inspection of spacecraft and the additive manufacturing of spacecraft repairs. She holds a bachelor’s degree in mechanical engineering from the University of Akron and is currently pursuing her Ph.D. in in-space inspection, focusing on 3D scanning and additive manufacturing for spacecraft replacement parts and hull damage repairs. Kayla has contributed to several projects on the development of novel on-orbit servicing, assembly, and manufacturing (OSAM) platforms, with a particular emphasis on inspection, manufacturing, and robotic technologies. In addition to her research, she has completed two internships through the Air Force Research Laboratory (AFRL) Scholars program, gaining practical experience while working alongside field experts.

Authors:

Kayla Dremann University of Akron
Isabelle Davis University of Akron
Motaz Hassan University of Akron
Ashton Orosa University of Akron
Ajay Mahajan University of Akron
Xiaosheng Gao University of Akron
Siamak Farhad University of Tennessee in Knoxville