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The geosynchronous satellite’s robotic servicing payload is housed in a cryogenic thermal vacuum chamber at the Naval Space Technology Center. | Credit: Sarah Peterson, U.S. Navy
Satellites in geostationary orbit, about 22,000 miles above Earth, are critical to military, government, and commercial communications, as well as Earth observation science. The Naval Research Laboratory (NRL) and the Defense Advanced Projects Agency last month completed development of a family of spaceflight-qualified robots capable of servicing satellites in orbit.
With DARPA funding, the lab’s Naval Space Technology Center (NCST) developed the Robotic Services (RSGS) Integrated Robotic Payload (IRP). The organization delivered this new space capability to its commercial partner, Northrop Grumman’s SpaceLogistics. The company plans to integrate the robotic payload with its spacecraft bus, the Mission Robotics Vehicle (MRV).
“The completion of the recent thermal vacuum test marks an important milestone in achieving the program goal of demonstrating robotic servicing capabilities in orbit in the near future,” said NRL Research Director Dr. Bruce Danly.
“NRL’s contribution to robotic payloads is essential to realizing this vision, which promises to transform satellite operations in geostationary orbit, reduce costs for satellite operators, and enable capabilities far beyond what we have today. “It’s a part,” he continued. “In fact, the anticipated capabilities are potentially revolutionary for both national security and civilian applications.”
NRL has a long-standing relationship with academia and industry as a collaborator and contractor. Participates in technology transfer efforts, including commercial licensing, collaborative research and development, and educational partnerships.
The Science and Engineering Command is dedicated to research for the U.S. Navy and Marine Corps, from the undersea to the space and intelligence domains. NRL is headquartered in Washington, D.C., with its primary site located at the Stennis Space Center in Mississippi. Key West, Florida; and Monterey, California. It employs approximately 3,000 civilian scientists, engineers and support staff.
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NRL aims to create satellite service opportunities.
The current spacecraft faces serious challenges in part because it cannot perform in-orbit repairs or upgrades. To compensate for insufficient servicing options, satellites are often equipped with backup systems and excess fuel, increasing complexity, weight, and cost.
“The military regularly repairs damaged aircraft, tanks, ships and trucks,” said Dr Glen Henshaw, senior scientist for robotics and autonomous systems at NRL. “We upgrade our aircraft and ships with the latest radars, computers and engines.”
“Satellites are the only expensive equipment we buy that cannot be repaired or upgraded once they are fielded, costing taxpayers money,” he added. “RSGS is intended to change this situation. “We plan to demonstrate that robots can be used to upgrade and repair these valuable assets.”
As DARPA’s robotic payload developer for the RSGS program, NRL sought to design, build, integrate, and test new satellite servicing capabilities. If the project is successful, the satellite could receive in-orbit upgrades to extend its service life, said Bernie Kelm, spacecraft engineering division supervisor at NRL NCST.
“This collaboration opens new service opportunities for both commercial and government satellites, enabling routine overhauls, orbit adjustments, hardware upgrades and repairs,” he said. “We have created advanced spaceflight hardware and software that will significantly enhance satellite service operations, including all robotic controls.”
Steven Butcher, space robotics and mechanisms engineer with Technology Service Corp., inspects the RSGS payload after completing testing at NRL’s Naval Space Technology Center. | Credit: Sarah Peterson, U.S. Navy
Thermal Vacuum (TVC) Test Process Information
The test campaign put the robotic payload through the temperature range it would encounter while in orbit and in space-like vacuum conditions. Engineers tested all aspects of the payload, including avionics, cameras and lighting.
We also demonstrated all operations using each of the two robotic arms, including firing lock deployment, calibration, and tool changes. These tests also validated SpaceWire communication, robot compliance, and visual servo control modes.
NRL has worked for over 20 years to mature the technology that makes the RSGS program possible. The goal is to safely and reliably repair and upgrade satellites, some of which cost more than $1 billion.
In the near future, robotic satellite “dynamics” could extend the useful life of satellites through new electronics, propulsion or sensor capabilities, NRL said. The RSGS robot could demonstrate a wide range of services as a precursor to building large-scale structures in orbit, such as observatories or solar power plants, the researchers said.
Expected to launch in 2026 from Northrop Grumman’s MRV spacecraft bus, the robotic payload will undergo initial checks and calibration with a full operational service mission.
“NRL’s Team RSGS has been focused for nearly a decade on the goal of completing this first robotic service payload,” said William Vincent, NRL RSGS program manager. “The completion of the IRP TVAC is a tremendous milestone and represents countless hours of work by an incredible group of dedicated people. Much like sending a child off to college for the first time, shipping an IRP to Dulles is a bittersweet experience.”
Once in orbit, the RSGS payload will inspect and service satellites in geostationary orbit. | Source: Sarah Peterson, U.S. Navy
