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DOCKING MECHANISM
Submitted in Partial Fulfillment of the Requirements for the Degree of
Bachelor of Technology
in
Aerospace Engineering
by
ADITYA KARAN
SC08B007
BONAFIDE CERTIFICATE
This is to certify that this project report entitled DESIGN AND
to
Indian
Institute
of
Space
Science
and
Technology,
K Kurien Issac
K.G. Vinod
Dy. Manager
Senior Professor
Mechanisms Lab
AMFD/ASMG/MVIT
VSSC, Valiamala
Technology
Valiamala, Thiruvananthapuram
U.A. Subramanian
Division Head
SSMD/ASMG/MVIT
Vikram Sarabhai Space Centre, Valiamala
Place: Thiruvananthapuram
Date: 2nd May, 2012
Declaration by author
This is to declare that this report has been written by me. No part of the report is plagiarized
from other sources. All information included from other sources has been duly
acknowledged. I aver that if any part of the report is found to be plagiarized, I shall take full
responsibility for it.
Place: Thiruvananthapuram
Date: 2ndMay, 2012
ADITYA KARAN
SC08B007
iii
ACKNOWLEDGEMENT
A small step in the field of technology requires great support & expert guidance. It was a very
rich experience for me to do my final year project at Vikram Sarabhai Space Centre (VSSC).
This project is a culmination of the studies and efforts of lot of people along with myself and I
would like to thank all of them profusely. First of all, I would like to thank Dr. R.V. Ramanan,
Adjunct Professor, Dept. of Aerospace, IIST, for having facilitated the availability of resources
and guidance for the realization of my project.
I sincerely thank to M. Premdas, Group Head, ASMG and P. Purushothaman, Division Head,
AMFD for their full support during the project.
I would like to deeply thank Sri U.A. Subramanian, Division Head, SSMD/ASMG/MVIT,
VSSC, Sri K.G. Vinod, Deputy Manager, Mechanisms Lab, AFMD/AFMG/MVIT, VSSC and
Dr. K. Kurien Issac, HOD, Dept. of Aerospace, IIST, for their invaluable guidance and support
throughout the duration of this project and their patience in helping to achieve the objectives. I
express my thanks to K P Venkateswaran, ASMG/MVIT for his helpful discussion time to time.
I would also like to thank Sri K. Thomas Varghese, IIST, and Shri Vinil Kumar for their
priceless support during the design stages (both on-paper and hardware designs). I would also
like to extend my thanks to Messrs. Aman Raj Verma, K. Kiran Sagar, Lala Surya Prakash,
Nitish Kumar, Sane Aakash, my colleagues from the Dept. of Aerospace and Mr. Kushagr
Gupta, from the Dept. of Avionics, for their support and help in this project. Last, but far from
least, I would like to thank those whose names have escaped mention above, but who have all
contributed in the successful completion of this project.
iv
ABSTRACT
Docking technology has got wide range of applications in ISROs future missions. The objective
of this project is to configure and design a docking mechanism suitable for a piggyback payload.
The misalignments specified have to be corrected and docking has to be made through reception,
guiding, capture and hard docking. For this the initial reception and guiding is achieved by a
typically outward petals and integrated capture and hard docking through a four bar mechanism.
This report elaborates on the misalignment range, configuration of petal and how it is arrived at.
Also detailed mechanism synthesis with velocity and acceleration profile is also presented. Both
the capture and docking is integrated into one mechanism and is driven by a variable speed
motor with redundancy. The mechanism is located inside the petals. Force analysis is done to
estimate the input torque. Further plan of action for making this concept as an autonomous
docking module is also designed.
Table of Contents
ACKNOWLEDGEMENT ............................................................................................................ iv
ABSTRACT ....................................................................................................................................v
LIST OF FIGURES .................................................................................................................... viii
INTRODUCTION .....................................................................................................................2
1.1 Problem Statement ..................................................................................................................2
1.2 Rendezvous and Docking/Berthing (RVD/B) Of Spacecraft ....................................................2
1.3Docking& Berthing ..................................................................................................................2
1.3 Differences &Similarities between Docking & Berthing ..........................................................3
1.4 Docking Operations.................................................................................................................3
1.5 Design Driving Requirements .................................................................................................5
1.5.1
1.5.2
vi
3.2.2
3.2.3
3.2.4
3.3.2
3.3.3
3.3.4
CONCLUSION .......................................................................................................................47
Appendix 1 ....................................................................................................................................48
Appendix 2 ....................................................................................................................................55
Appendix 3 ....................................................................................................................................59
Appendix 4 Fabrication Drawing .................................................................................................63
REFERENCES .............................................................................................................................70
vii
LIST OF FIGURES
Figure 1.2.1 Space Shuttle Docked with ISS courtesy NASA ...................................................................... 2
Figure 1.2.2 Dragon Spacecraft during Berthing with ISS courtesy NASA .................................................. 3
Figure 1.6.1 Central Docking Mechanism Schematic ................................................................................ 6
Figure 1.6.2 Peripheral Docking Mechanism Schematic Ref (1) ................................................................ 6
Figure 2.1.1 Probe-Drogue Docking System [2] ........................................................................................ 7
Figure 2.1.2Probe & Drogue Docking System courtesy NASA ................................................................... 8
Figure 2.1.3 Docking Sequence in Central Probe type System [3] ............................................................. 8
Figure 2.2.1 Ring & Cone Docking System [2] ........................................................................................... 9
Figure 2.3.1 Gemini Docking System [2] ................................................................................................... 9
Figure 2.4.1Inflatable Probe [2] ............................................................................................................. 10
Figure 2.5.1 Inflatable Tunnel [2] ........................................................................................................... 10
Figure 2.6.1 V-Latch ............................................................................................................................... 11
Figure 2.6.2Positioning of V-Latches [1] ................................................................................................. 11
Figure 2.7.1 APDS Schematic [2] ............................................................................................................ 11
Figure 2.7.2 Active side of APDS [4] ....................................................................................................... 12
Figure 2.7.3 Passive Side of APDS [4] ..................................................................................................... 12
Figure 2.7.4 Active Capture Latch [1] courtesy ESA ................................................................................ 13
Figure 2.7.5 Screw type latch (courtesy ESA).......................................................................................... 13
Figure 3.2.1 Expandable Cone type Guiding System ............................................................................... 15
Figure 3.2.2 Rotating type outward Petal configuration before contact ................................................. 16
Figure 3.2.3 Initial Petal configuration with Docking Coordinate system ................................................ 17
Figure 3.2.4 Petal Configuration after Euler Transformation with increased length ................................ 18
Figure 3.2.5 interference 1 between petals =46 config ........................................................................ 19
Figure 3.2.6 interference 2 between petals =46 config......................................................................... 19
Figure 3.2.7 interference 3 between petal and ring =46 config............................................................. 20
Figure 3.2.8 guiding system configuration =55 &=73 ......................................................................... 20
Figure 3.2.9 final petal configuration with all lateral (along different directions) & angular misalignments
.............................................................................................................................................................. 21
Figure 3.2.10 Snapshots of Simulation of Contact & Guiding by petals ................................................... 23
Figure 3.3.1 schematic of One of three probe with cone ....................................................................... 24
Figure 3.3.2 Schematic of rotating arm catching petal ........................................................................... 25
Figure 3.3.3 rotating arm Locked Position .............................................................................................. 25
Figure 3.3.4 locus of mechanism output link .......................................................................................... 25
Figure 3.3.5 locus of capturing point final configuration ........................................................................ 26
Figure 3.3.6 Toggle condition in coupler point( no torque position) ....................................................... 27
Figure 3.3.7 Stable position , torque on input link is having tendency to close the mechanism............... 27
Figure 3.3.8 Mechanism position, velocity &.......................................................................................... 28
Figure 3.3.9 Locus of links from 106 deg to 285 input angle ................................................................... 29
Figure 3.3.10 Capture/ready position of Mechanism (input angle 122 deg)............................................ 29
viii
ix
1 INTRODUCTION
1.1 Problem Statement
As Future Missions of ISRO, where assembly of Modules may take place in the orbit, Docking
Technique is going to be a key element. This project deals with Design & Development of
Docking Mechanism which can Capture, Guide, Dock & Undock 600kg & 160 kg Spacecrafts
in the orbit.
A space rendezvous is an orbital maneuver during in which two spacecraft arrive at the
same orbit and approach to a very close distance (e.g. within visual contact). Rendezvous
requires a precise match of the orbital velocities of the two spacecraft, allowing them to remain
at
constant
distance.
Rendezvous
was
first
successfully
accomplished
in Dec
1965when Gemini 6 spacecraft was brought within 1 foot (30 cm) of its sister craft Gemini 7.
RVD/B systems are key elements in missions such as
Assembly in orbit of larger units& Re-supply of orbital platforms and stations (eg. ISS, Mir)
Exchange of crew in orbital stations
Capture, Repair& placing of spacecraft in orbit (Hubble Telescope repair by Space Shuttle)
Retrieval, i.e. capture and return to ground, of spacecraft; eg EURECA Spacecraft
Re-joining an Orbiting Vehicle using a lander in the case of Lunar and Planetary return
Missions; eg Apollo Mission
Rendezvous may or may not be followed by physical contact between Spacecrafts. As a general
term for the process of achieving rigid connection between two Spacecrafts, the term mating is
used. This includes Docking and Berthing.
1.3Docking& Berthing
The term Docking is used
When the GNC (Guidance,
Navigation
System
of
&
the
Control)
Chaser
that
its
capture
Target
Vehicle,
and
2|Page
spacecraft took place onMarch1966, when Gemini vehicle was docked with an unmanned Agena
target vehicle.
In case of Berthing, the GNC system of
the Chaser delivers the vehicle at
nominally zero relative velocities and
angular rates to a meeting point, where
a manipulator, located either on the
target or chaser vehicle, grapples it,
transfers it to the final position and
inserts it into the interfaces of the
relevant target berthing port.
courtesy NASA
acquisition of the docking axis, the chaser reduces its approach velocity to the final value.
The last part of the approach is done with constant Velocity. During the last few meters
of approach the chaser GNC must achieve the lateral and angular alignment which is
3|Page
necessary to place docking interfaces of chaser and target into each others reception
range.
Reception. This is the range within which physical contact between the two vehicles
occurs and capture of the according interfaces is possible. The reception range must be
large enough to cover all remaining misalignments of the chaserw.r.t. the target vehicle.
Impact attenuation. After the first contact, remaining kinetic energy of Chaser has to
be absorbed for avoiding its rebound. With Spring damper devices velocity change
occurs over a longer distance which reduces shock load on structures and increase time
available for capturing process
Capture. After entering into their reception ranges, the capture interface structures of
both sides can guide each other into the conditions of alignment, at which capture can be
completed. The term capture simply means that the vehicles can no longer escape from
each other. It does not imply, however, that a rigid connection has been established.
Operation of the capture latches can be achieved either by springs latches (passive type
latches) and the kinetic energy available from the residual velocity between chaser and
target or by actuation of active latches initiated by sensors (can be contact, force or visual
type sensors).
Retraction and structural alignment. After capture, the two spacecraft are still only
relatively loosely connected to each other, and the axial distance, the lateral and angular
misalignments in general may not allow immediate engagement of the structural latches.
On the other hand, in most designs, the springs of the shock attenuator system will push
the two bodies away from each other. For this reason, in most designs a retraction
mechanism is necessary to pull the docking interface planes of the two craft together also
improving the misalignment necessary for structural connection.
Structural connection. Once Spacecrafts are properly aligned, the structural latches
can be engaged. They press the two interface planes together under a pre-load to ensure a
stiff structural connection under all load conditions which potentially could occur during
operation as a combined spacecraft. Structural latches also have to apply the compression
forces for the sealing rings when pressurized connection is needed between spacecrafts.
4|Page
Velocity and
5|Page
system on other spacecraft. This type of design is called Androgynous Peripheral Docking
System (APDS).
APDS technology came when Apollo-Soyuz program started. This mission consisted of Docking
of American Apollo Command Module with Russian Soyuz Module as to check compatibility of
both countries technology before starting for an orbital Station Mission and still used in ISS &
Space Shuttle Docking.
6|Page
entering into the capture hole, the springloadedcapture latches on the tip of the rod will engage
on the flange inside the entranceof the hole. Alignment between the two vehicles is achieved
during retraction of the rod.
7|Page
which
engage
after
was
and
used
for
ATV
Apollo
(automatic
8|Page
contact
to
capture
latch
engagement and is removable, after hard docking, to provide for crew transfer. In addition a slot
in the cone was provided such that a guide bar on the capsule provided accurate rotational
alignment of the vehicles.
9|Page
The
tube
is
rigid
by
gas
in
the
drogue.
10 | P a g e
2.6 V Latches
For uncompressed Docking, this type of Mechanism is
used. This was used in ETS-7 satellite of Japan. This can
be central of peripheral type. This typically consists of
three or four latches arranged on the mating ring of the
active vehicle, with handlebars as interfaces for the
latches on the side of the passive vehicle. The latch
consists of a V-shaped guiding structure and two arms,
which after closure will prevent escape of the handlebar
and will pull it down into its seat.
from
the
ring) bysix dampers arranged in a Stewart platform setup.On the active side, the dampers are
extended; on the passive side theyare retracted. Each contact ring has 3 Petal, which can be
11 | P a g e
These
capture.
carries
Eachpetal
spring-loaded
After
corresponding
catches.After
successful
the
docking
ringare
used.
Capture latches in APDS
can be passive or active.
of APDS [4]
Magnetic latch is example of passive latches. Active type latches are motor driven which
actuates with the help of sensors.
One active latch used for Hermes-Columbus docking system by ESA is four bar mechanism
(figure 2.7.4).
12 | P a g e
This four bar mechanism has extended coupler link which capture the other spacecraft and bring
it closer for docking mechanism to take over for rigid connection.
Structural latch can either be of hook type or screw type. In screw type latches, both bolt and nut
are mounted on spherical bearings to
compensate misalignments.
13 | P a g e
Allowable relative axial velocity of Chaser w.r.t target is 5-10cm/s. lateral velocity
below 5cm/s & angular velocity below 0.5 deg/s.
When both spacecrafts Docking rings are at 100mm (Axial Reception), allowable
lateral misalignment is 85mm.
Allowable roll, pitch & yaw at 100mm is 5 deg each about Coordinate System, the
origin of which lies in the intersection of Longitudinal Axis of Spacecraft & mating
plane of Docking system.
At the end of docking process, there must be a rigid connection between the modules. Any
disturbance should not lead to failure/opening of this connection. No power should be provided
to keep this rigid connection. Power should be used only in docking/undocking process. All
mechanisms should be driven by single motor with redundant motor. In previous mission, in
which peripheral docking system was used, separate mechanisms have been used for Capturing
& Docking Purpose. In the proposed Mechanism, Same mechanism should be able to perform
Capture & Dock (rigid connection).
14 | P a g e
will work as
as
shown
in
penalty
in
mass
and
15 | P a g e
complexity. Also this locking will take a lot of space inside the tunnel. This configuration
doesnt fulfill our requirement of single Capture & Docking system.
configuration
consists
of
When
these
petals
angular
misalignments.
work
as
structural
connection too.
Figure 3.2.2 Rotating type outward Petal configuration
before contact
plate is used. There is arrangement for latches in the petal.so that petal can fall into latch catch
located on the other ring to get a capture. Proposed capture/docking mechanism has to be
16 | P a g e
accommodated within the petal. So design of hollow petal is proposed. Hollow petal either can
be made by plate or by bending tube in desired shape. Due to the time constraint, tube type petal
design is taken in consideration. For making tube type petal, only bending of tube and
arrangements for fixtures with ring is needed. Other time taking fabrication activities can be
avoided in this configuration. Petal should be strong enough for impact load when petal-petal or
petal-ring comes into contact.
As reception range given is 100mm, which means if petal length along longitudinal axis is more
than 50mm, spacecrafts cant escape each other except in the case of rebound. For starting the
configuring petals, initial vertical length of petal is taken as 50 mm. Petal can correct lateral
misalignment equal to its radial length. As 85mm lateral misalignment is to be corrected, petal
radial length is 85mm. this is the initial configuration of petals.
Now this system should be able to correct angular misalignment. At 100mm angular
misalignments (5deg each in roll, yaw & pitch) will give additional radial & longitudinal
distance which should be covered by petals.
Coordinate system for docking system is defined as located on the center of the ring interface
with Z axis along the vehicle longitudinal axis. All misalignments are w.r.t this coordinate
system.
17 | P a g e
A=
( cos z )
( sin z sin y + cos z sin x cos y )
( sin z cos y + cos z sin x sin y )
( cos x sin y )
( sin x )
( cos x cos y )
X '
X
Y ' = A Y , where x, y & z represents yaw, pitch & roll
Z '
Z
X , Y & Z coordinates of po int s on ring or petal before transformation
X ', Y '& Z ' coordinates of po int s on ring or petal after transformation
MatLab program was developed for transformation (see Appnedix-1). 12 points on rings & edge
points on petals were taken. Then the ring 2 was given all angular misalignments w.r.t Docking
coordinate system and the displacements were found radially and axially ring to ring and petal to
petal. With these
R petalMAX = 8.05 mm
R ringMAX =15.21mm
Z petalMAX = 46.70mm
Z ringMAX = 36.42 mm
New Petal configuration is as following.
ZPetal =+
50 46.70 =
96.70mm
R Petal =+
85 15.21 =
100.21 mm
Figure 3.2.4 Petal Configuration after Euler Transformation with increased length
18 | P a g e
to have an initial value for the base line configuration of petals, Euler transformation is used.
Later different combinations of lateral & angular misalignments were tried graphically and an
acceptable configure is arrived at with almost zero interferences for the misalignments specified.
This is also accounted the space required for accommodating capture/docking mechanism.
19 | P a g e
20 | P a g e
Fig-a
Fig-b
Fig-c
Fig-d
Figure 3.2.9 final petal configuration with all lateral (along different directions) & angular misalignments
21 | P a g e
Coulomb Friction
Mu Static
Mu Dynamic
: 0.3
: 0.1
22 | P a g e
23 | P a g e
(a)
24 | P a g e
when
spacecrafts
come
Figure 3.3.2 Schematic of rotating arm catching petal
range.
Before
first
system,
docking
25 | P a g e
coupler
link
appendix
configuration
of
2).
Final
four
bar
mechanism is as following.
l1=52.50 length of the link 1
l2=76.25 length of the link 2
l3=77.49 length of the link 3
l5=89.59 length of the link 4
fixed with link 3(coupler)
l4=62.27 length of capturing
link 5
This mechanism has axial
capture range as 100mm.
This design also gives the
26 | P a g e
27 | P a g e
0= tan 1 ( x3 x1 y3 y1 )
x1 =0,y1 =0
x 2 =l1 cos(1 ) (joint 2)
y 2 =l1 sin(1 )
J 2 =complex(x 2 ,y 2 ) coordinate of joint 2
J 2 -J 3 represents J 3J 2 vector
e=abs(J 2 -J 3 ) magnitude of J 3J 2 vector
=
4 angle( J1 J 3 ) angle( J 2 J 3 )
3 =angle(J 4 -J 2 )
f 1 =34.80 /180 fixed angle between J 4 J 5 & J 4 J 6
(l4 2 + l52 )0.5
lJ 4=
J6
J4J6 = f 2 -( -3 + f 1 )
J4J5 = f 2 -( -3 )
co ordinates of capture point (output point 6)
x 6 =x 4 +(lJ4J6 cos J4J6 )
y6 =y 4 +(lJ4J6 sin J4J6 )
coordinates of point 5
x 5 =x 4 +(l4 cos J4J5 )
y5 =y 4 +(l4 sin J4J5 )
28 | P a g e
Figure 3.3.9 Locus of links from 106 deg to 285 input angle
Mechanism
29 | P a g e
3.3.4.2 Velocity
As shown in above figures that mechanism will be kept in retracted position from where it
actuates to acquire its capture position so that in any case of rebound, ring of 2nd spacecraft cant
escape. Assuming impact time as 100ms, mechanism should be fast enough to get its capture
position from retracted position within 50ms. This requirement defines the input rotation of
mechanism. From figure (3.3.12) input RPM is taken as 50. After reaching the capture position,
Figure 3.3.12 Time taken for Mechanism to reach its capture position from Retracted position with input RPM
as 50
its RPM can be reduced to avoid high impact load between link and ring. With input RPM as
50, velocity of output link can be found as following.
In Figure (3.3.8), replacing links 1, 2, 3 & fixed link (J3J1) by their corresponding vectors and
taking vector summation, Equation is as following.
J 3 J1 + L1 + L3 L2 =
0
------(1)
in complex form
0 ----(2)
J 3 J1e j ( pi /2+0 ) + L1e j (1 ) + L3e j (3 ) L2e j (6 ) =
as J 3 J1 is a fixed link, first time derivative of Eqn (2) is
jL1 e
j (1 )
+ jL3 e
j (3 )
jL2 e j (6 ) = 0
6
=
w=
w4
1 w=
2 , 3
3 , 6
30 | P a g e
w3 =
l1 w 2 (sin(1 - 6 )
----------(3)
l3 sin( 6 -3 )
w4 =
l1 w 2 (sin(1 -3 )
----------(4)
l2 sin( 6 -3 )
Link 3, 4 & 5 are having the same rotation velocity as w3. With relative vector, output velocity
can be found as following.
VJ2 =(w 2 J 2 J1 )
31 | P a g e
2J1
A nJ
4J 2
=w 2 (w 2 J 2 J1 )
=w 3 (w 3 J 4 J 2 )
A nJ4J3 =w 4 (w 4 J 4 J 3 )
A nJ
6J 4
=w 3 (w 3 J 6 J 4 )
Tangential accln
At= J
AtJ
2J1
=0 constant w 2
AtJ J= 3 J 4 J 2
4 2
t
A J J=
4 3
4 J 4 J 3 (unknown 3 & 4 )
+ AtJ
2J1
4J 2
+AtJ
4J 2
--------(6)
4 J3
+ AtJ
--------(7)
4 J3
2J1
+ AtJ
4J 2
+AtJ
4J 2
=A nJ
4 J3
+ AtJ
4 J3
AtJ
4J 2
= 3 J 4 J 2
AtJ =AtJ
4
4J 2
+AtJ
2J1
AtJ J= 3 J 6 J 4
6 4
t
A J6 =AtJ
4
+AtJ
6J 4
32 | P a g e
A nJ =A nJ
4
4J 2
+A nJ
A nJ =A nJ +A nJ
2J1
6J 4
n
A 6x =A J (x)+AtJ ( x)
6
6
n
t
A 6y =A J (y)+A J ( y )
6
6
6
+F
A
3 F
M =
6y
M
1
2
33 | P a g e
34 | P a g e
1 mv 2 0.5
=
=
1600.052 0.2 J
2
This energy has to be imparted by means of three spring attached on the interface of ring.
0.2 = 0.5k x 2 3
for x=10 mm stroke of spring
k=1333 N/m
which gives total F=k x 3=40N
35 | P a g e
5
P 10
=
N/m (1 Bar), r 0.2m
total
=
force
P r )
(=
2
105=
0.22 12566.37 N
of output link
Figure 3.3.19 FBD
of link 2
36 | P a g e
Given Fy ,Fx
2 force & 1 Moment Equilibrium Equations
Fy2 + Fy3 =
Fy ------------Eqn. 9
Fx2 + Fx3 =
Fx----------------Eqn. 10
M joint4 =0 gives
[ Fx( y6 y4 ) + Fy ( x6 x4 )]--------Eqn. 11
Fx2 ( y2 y4 ) + Fy2 ( x2 x4 ) =
as link 2 is free to rotate. no moment is applied on this link.
load on this link will be only axial type which givesFx3 (tan( + 6 )) Fy3 = 0--------------Eqn. 12
which gives us
A1 F = B1 ------(13)where
1
0
A1 =
( y2 y4 )
( x2 x4 )
tan( + 6 )
1
1
Fx
Fx 2
Fx3
Fy
B1 =
& F=
Fy 2
-(Fy(x 6 -x 4 )+Fx (y6 -y 4 ))
Fy 3
by solving Equation (13), Fx 2 ,Fy 2 ,Fx 3 ,Fy3 can be found.
Torque on link 1
r Ri wi
winput
r pin radius
friction coefficient
Ri reaction force at i th joint =
( Fxi 2 + Fyi 2 )
wi relative w of links at i th joint
of Input Link
37 | P a g e
MATLAB program was developed for torque calculation and for both cases (single mechanism
capturing & all mechanisms capturing simultaneously) torque needed for motor is as following.
Velocity & acceleration profile for contact part (input angle 122 deg to 285 deg)
Figure 3.3.21 Vertical velocity of joint 6 from contact position till final position
Figure 3.3.22 Vertical acceleration of joint 6 from contact position till final position
38 | P a g e
39 | P a g e
Figure 3.3.25 total torque on input link of one mech (all mechanisms capturing)
40 | P a g e
Figure (3.3.25) shows the toggle condition at 270 deg. at this angle torque coming on input angle
is zero. Beyond this point torque coming on this link changes its direction which means if
mechanism is kept beyond this point, any force coming on output point would not be able to
open the mechanism (clockwise torque is needed for opening the mechanism, beyond this point
any disturbance force on output link, mechanism will face anticlockwise torque.) this is why
mechanism will rest at 285deg input angle. Vertical displacement from 270 to 285 deg is only 1
mm. peak in the force & torque graph (Figure 3.3.23 & 3.3.24) at 228 deg is coming as at this
point spring/seal compression will start.
Figure 3.3.27 total force on one mechs output link (single mech. capturing)
41 | P a g e
Figure 3.3.28 torque on one mechs input link (single mechanisms capturing)
42 | P a g e
Torque shown above are for one mechanism only. Maximum Torque needed for one mechanism
in single capturing case s approx. 16Nm. So motor (which will drive all mechanism) should have
48Nm torque.
Calculating min Area & Inertia of Links/Pins
(h / 2)
M2
Al
43 | P a g e
= 4535.3N
Fx =
=
Fy , 0.1(assumed )
rpinmin = 1.75 mm
rpin1min =3.80 mm
with fa c tor of m arg in
rpinmin = 3 mm (FoM=1.7)
rpin1min =5 mm (FoM=1.3)
link 1 & coupler link cross section(10x10mm)
link2 cross section(5x14mm)
Figure 3.3.31 mechanism at270 & 285 deg(resting position)
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3.5 Fabrication/Integration
Fabrication drawings are generated for
Guiding
Petal,
mechanism.
capturing/docking
Accommodation
of
the
petal
(figure
3.5.1).
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4 CONCLUSION
Wide Literature survey was carried out for docking systems [1, 2, 3]. Various options for guiding
and docking systems were explored and compared based on their advantages and disadvantages.
The design which fulfills the mission requirements was chosen for further analysis. Typical
outward type petal is chosen for guiding system and configured for the misalignments given.
ADAMS analysis was done to check the performance of guiding petals when misalignments are
present and was found working satisfactory. For integrated capturing and docking system, four
bar mechanism with extended coupler link was chosen and sizes were determined according to
capture range requirement. Three such mechanisms are used. Based on force analysis total torque
required for driving the mechanism by a single motor is found to be 48 Nm. Cross section of the
linkages of the mechanism are determined by structural analysis of individual linkages.
Mechanisms are located within the space available inside the petal. Fabrication drawings are
generated for both the systems and assembled. The fabrication of docking rings is completed and
that of mechanism and petals is in progress.
Future Plans
Contact dynamics
47 | P a g e
Appendix 1
Euler transformation for Petal/Ring
clear all
clc
% initial Petal Design parameters
% Z=50 mm because Axial Range is 100 mm (petal edge distance from origin
in Z direction)
% lateral Misalignment =85 mm, thus radial length of Petal 85 mm
% angle of the petal from Z axis beta 59.53 deg outward
% Roll Misalignment as 5 deg which gives alpha angle as 68 deg inward
% angle projected by extreme points (on the edge of the petal) on the
center of the circle (made by petals edge points) 17.35 deg
% with these initial parameters, pitch & yaw (5 deg each) given when rings
are 100 mm apart%
%-------------------------------------------Petals on RING 1-----------------------------------------%
R1=385; % radius of the circle nade by extreme points of the petals
(center of this circle is 0,0,50)
th1_petal=[-8.675 8.675 111.325 128.675 231.325 248.675 ]'; % angle by
these points on the center
Z1=50; % vertical length of the petal %
for i=1:3
for j=1:6
if i==1
R1_petal(i,j)=R1*cosd(th1_petal(j));
end
if i==2
R1_petal(i,j)=R1*sind(th1_petal(j));
end
if i==3
R1_petal(i,j)=Z1;
end
end
end
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R_ring1(i,j)=Z_ring1;
end
end
end
%---------------euler
%
tx=5*pi/180;% pitch
ty=5*pi/180;%yaw
tz=5*pi/180;%roll
cx
sx
cy
sy
cz
sz
=
=
=
=
=
=
transformation--------------------------------------
cos(tx);
sin(tx);
cos(ty);
sin(ty);
cos(tz);
sin(tz);
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R2_disp_ring2=(x1_ring2.^2+y1_ring2.^2).^0.5(x1_ring2_NEW.^2+y1_ring2_NEW.^2).^0.5
z1_ring=(z1_ring2-z1_ring2_NEW) % don't be confused..this is for 2nd ring,
not for 1st ring.%
%----------------------------------------------------------------------------%
% coordinates of outer most edges of petals attached to ring1%
g=1:6;
x1_petal=R1_petal(1,g);
y1_petal=R1_petal(2,g);
z1_petal=R1_petal(3,g);
%----------------------------------------------%
m=1:438;
% coordinates of outer most edges of petals attached to ring2%
x2_petal=R2_petal(1,m);
y2_petal=R2_petal(2,m);
z2_petal=R2_petal(3,m);
% coordinates of outer most edges of petals on ring2 after pitch & yaw%
x2_petal_NEW=R2_petal_NEW(1,m);
y2_petal_NEW=R2_petal_NEW(2,m);
z2_petal_NEW=R2_petal_NEW(3,m);
%---------------------------------------------------------%
p=1:73;
% coordinates of the mid points of the petals at periphery of ring1%
x1_ring1=R_ring1(1,p);
y1_ring1=R_ring1(2,p);
z1_ring1=R_ring1(3,p);
R1_petal;
R2_petal
R2_petal_NEW
R_ring1;
%-------displacement of 2nd rings & points on the petals--------%
R2_disp_petal2=(x2_petal_NEW.^2.+y2_petal_NEW.^2).^0.5(x2_petal.^2.+y2_petal.^2).^0.5
R2_disp_ring2=(x1_ring2_NEW.^2+y1_ring2_NEW.^2).^0.5(x1_ring2.^2+y1_ring2.^2).^0.5
R2_petal_MAX=max(abs(R2_disp_petal2))
%R2_ring_MAX=max(abs(R2_disp_ring2))
[R2_ring_MAX,indx_Rring]=max(abs(R2_disp_ring2))
z2_petal_MAX=max(abs(z2_petal-z2_petal_NEW))
[z2_petal_MAX,indx_ZPetal]=max(abs(z2_petal-z2_petal_NEW))
%z1_ring_MAX=max(abs(z1_ring))
[z1_ring_MAX,indx_Zring]=max(abs(z1_ring))
%----------------------------Result---------------------------------------
R petalMAX = 8.05 mm
R ringMAX =13.65 mm
Z petalMAX = 46.70mm
Z ringMAX = 36.42 mm
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=
=
r 300,
lPetalRadial 85
=
a
2 300 )
(=
( 23)
314mm
= 680 inward
52 | P a g e
When 55 deg as taken for beta angle, alpha angle calculation is done again. Yaw, pitch and
lateral misalignment will also contribute in deciding alpha as following which is not taken in
initial calculation.
a = 298.14mm,
R1 = 300mm,
R 2 = 371.4mm
= 550
initial = 650
b = 216.85mm
Iteration
for
alpha is done
so that
2 R 2 (6b)
(contribution of lateral , roll & (pitch or yaw) misalignments) =
0
6
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( R2 5 )
( 2 R 2 (6b) ) ( 32+85+11.39
( 2 371.4 (6216.85) ) ( 32+85+11.39
=
=
)
)
6
43.68
Calculation was repeated for angle 65 to 75 to bring the remaining as zero. And 73 was
selected as alpha for beta as 55 deg.
final petal configuration is as following .
l petal = 185mm
= 730
= 550
a = 298.14mm
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Appendix 2
Four Bar Mechanism Development
Following figures shows the development of the mechanism which gives different locus of the
output point on coupler link.
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vertically.
This
means
when
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Configuration 5 This configuration almost fulfill given requirements. This has axial as well
as lateral range and the locus of the output point
is very similar to our required mechanism axial
& lateral range (figure 3.3.5).
(or
5 2 = 7.071deg
to
longitudinal axis of
ring.)
gives
37mm
displacement
for
57 | P a g e
shown in figure.
Coupler point will capture the 20mm thick ring which has to be added into the mechanisms
capture range. This gives 107 mm as a capturing range of mechanism.
Configuration has been done with 100mm as capturing range assuming some angular
misalignment would get corrected when rings reaches 50mm axial distance. Lengths of links are
as following
(refer A2.7).
l1=52.50 length of the link 1
l2=76.25 length of the link 2
l3=77.49 length of the link 3
l4=89.59 length of the link 4
fixed with link 3(coupler)
l5=62.27 length of capturing
link 5
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Appendix 3
MatLab Code for four bar mechanism
clear all
clc
%-----------references are given with respect to the design in SAM Software----%
l1=52.50; % lenght of the link 1
l2=76.25785; % lenght of the link 2
l3=77.49747; % lenght of the link 3
l4=89.59612; % length of the link 4 fixed with link 3(coupler)
l5=62.27176; % length of capturing link 5
th0=(atan(18.75/56.25)); % angle between fixed joints 1 & 3
%th1= input(' input angle for link 1');
%th1=210*pi/180; %final position after toggle point. o/p link is at 1.7 mm
%vertical disstance from toggle point
% th1=(228*pi/180);% compression of seal/spring starts
% th1=(122.7*pi/180):0.01:(270*pi/180);
th1=linspace(122.7*pi/180, 285*pi/180,500)
th1l=length(th1);
m1=600; %target spacecraft mass
m2=160;%chaser spacecraft mass
for s=1:th1l
J3=complex(-18.75,56.25); % co ordinates of fixed joint 3
x3=-18.75;y3=56.25;
J1=complex(0,0); % co ordinates of fixed joint 1
x1=0;y1=0;
x2=l1*cos(th1(s)) % position of end of input link (joint 2)
y2=l1*sin(th1(s))
J2=complex(x2,y2); % coordinate of joint 2 in complex form
e=abs(J2-J3); % e is the magnitude of vector from J3 to J2
th4=(-(angle(J2-J3)-angle(J1-J3)));
th5=(acos((e.^2+l2^2-l3^2)./(2*e*l2)));
th6=((1.5*pi)+th0-th5-th4); % angle made by vector J4J3 w.r.t. X axis
th34=th6-pi; % angle made by vector j3j4 w.r.t X axis
x4=-18.75+(l2*cos(th6))
y4=56.25+(l2*sin(th6)) % coordinate of joint 4
J4=complex(x4,y4); % coordinate of joint 4
%----some pblm below & in J4 also.... CORRECT ONLY FOR INPUT ANGLE 108 TO 270
DEG-------------------%
th3=(angle(J4-J2));
th_fixed1=34.80036*pi/180; % angle between J4J5 & J4J6
l_J4J6=(l4^2+l5^2)^0.5; % representative length of single link from J4 to J6
inplace of links 4 & 5
th_fixed2=126.53112*pi/180; % angle between J5J4 & J4J2;
th_link46=(th_fixed2-(pi-th3+th_fixed1)); % angle of link joining joint 4 & 6
w.r.t. X axis
th_link45=(th_fixed2-(pi-th3)); % angle of link joining joint 4 & 5 w.r.t. X
axis
% co ordinates of capture point (output point 6)
x6=x4+(l_J4J6*cos(th_link46))
y6=y4+(l_J4J6*sin(th_link46))
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% coordinates of point 5
x5=x4+(l4*cos(th_link45));
y5=y4+(l4*sin(th_link45));
%------------link Acceleration Analysis----------------------%
%-----------moment analysis for each part of links----------------%
% w2=input('insert the angular velocity (RPM)for input link 1');
w2=50;
w2=w2*2*pi/60;
w3=(l1*w2*(sin(th1(s)-th6))/(l3*sin(th6-th3))) % absolute angular velocity of
link 3
w4=(l1*w2*(sin(th1(s)-th3))/(l2*sin(th6-th3))) % absolute angular velocity of
link 2
% ----------link J5J6-------------------%angular velocities of link 3,4 & 5 are same.
% velocity of points on link
W2=[0 0 w2]; % vector form of angular velocity of link 1
W3=[0 0 w3];
W4=[0 0 w4];
R_J2J1=[x2 y2 0]*10^-3; % vector representation of link 1
R_J4J2=[(l3*cos(th3)) (l3*sin(th3)) 0]*10^-3; % link 3
R_J4J3=[(l2*cos(th6)) (l2*sin(th6)) 0]*10^-3; % link 2
R_J6J4=[(l_J4J6*cos(th_link46)) (l_J4J6*sin(th_link46)) 0]*10^-3; % link46 or
J4J6
% linear velocity of joints on links
V_J2=cross(W2,R_J2J1)
V_J4=V_J2+cross(W3,R_J4J2)
V_J6=V_J4+cross(W3,R_J6J4)%velocity of output link joint 6
V_J4J3=cross(W4,R_J4J3) % velocity of point 4 w.r.t. joint 3
V2x(s)=V_J2(1);V2y(s)=V_J2(2);V4x(s)=V_J4(1);V4y(s)=V_J4(2);
V6x(s)=V_J6(1);V6y(s)=V_J6(2);
% relative accln of joints
An_J2J1=cross(W2,cross(W2,R_J2J1)); % normal accln of link 2 ---(w2x(w2xR_J2J1)) double cross product
An_J4J2=cross(W3,cross(W3,R_J4J2))
An_J4J3=cross(W4,cross(W4,R_J4J3))
An_J6J4=cross(W3,cross(W3,R_J6J4))% normal accln of joint 6 w.r.t joint 4
At_J2J1=0; % constant W2
% alph=[alph3 aplh4];
A=[R_J4J2(2) -R_J4J3(2)
-R_J4J2(1) R_J4J3(1)];
B=[An_J2J1(1)+An_J4J2(1)-An_J4J3(1)
An_J2J1(2)+An_J4J2(2)-An_J4J3(2)];
alph=inv(A)*B;
alph3=[0 0 alph(1)] % angular accln of link 3,4 & 5 in vector form (there
angular velocity is same so the angular accln)
alph4=[0 0 alph(2)] % angular acclnn of link 2
At_J4J2=cross(alph3,R_J4J2)
At_J4=At_J4J2+At_J2J1
At_J6J4=cross(alph3,R_J6J4)
At_J6=At_J4+At_J6J4 % absolute tangential accln of joint 6
An_J4=An_J2J1+An_J4J2
An_J6=An_J4+An_J6J4 %absolute normal accln of joint 6
A6x=An_J6(1)+At_J6(1)
60 | P a g e
plot(th1*180/pi,V6y)
xlabel('input theta1','FontSize',12)
ylabel('Vy 6 (m/s)','FontSize',12)
title('\it{vertical velocity of joint 6}','FontSize',12)
figure(2)
plot(th1*180/pi,T_needed)% with out friction of links
xlabel('input theta1','FontSize',12)
ylabel('T needed (Nm)','FontSize',12)
title('\it{T needed without friction on joints}','FontSize',12)
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figure(3)
plot(th1*180/pi,T_joint)
xlabel('input theta1','FontSize',12)
ylabel('T joint (Nm)','FontSize',12)
title('\it{T joint}','FontSize',12)
figure(4)
plot(th1*180/pi,T_total)
xlabel('input theta1','FontSize',12)
ylabel('T total (Nm)','FontSize',12)
title('\it{Total Torque needed}','FontSize',12)
figure (5)
plot(th1*180/pi,A6y)
xlabel('input theta1','FontSize',12)
ylabel('A6y (m/s2)','FontSize',12)
title('\it{Y component of accln of joint 6}','FontSize',12)
figure (6)
plot(th1*180/pi,Fy6)
xlabel('input theta1','FontSize',12)
ylabel('Fy6 (N)','FontSize',12)
title('\it{Y component of force of joint 6}','FontSize',12)
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5 REFERENCES
[1]. Fehse, W, Automated Rendezvous and Docking of Spacecraft, Cambridge
University Press, 2003
[2]. Space Tug Docking Study, Supporting Analyses Final Report, NASA-CR-144242, 4,
Martin Marietta Corp.
[3]. Cislaghi, M and Santini, C, The Russian Docking System and the Automated Transfer
Vehicle-a safe integrated concept, 3rd IAASS Conference, 2008
[4]. http://dockingstandard.nasa.gov/images_NDS_Image_Gallery_1.html
[5]. Langley R D, Apollo Experience Report The Docking System , NASA Technical Notes
D-6854 Manned Spacecraft Center, Houston, 1972
[6]. Ezell, E C and Ezell, L N, The partnership-Apollo Soyuz Test Project The NASA
History series, 1978
[7]. International Docking System Standard (IDSS)-Interface Definition Document (IDD),
2011
[8]. Uicker Jr, J J, Pennock G R and Shigley, J E, Theory of Machines and Mechanisms
Oxford University Press, pp. 103-148, 2009
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