1. Orbital Express: A New Chapter In Space
Tracey M Espero
The Boeing Company

2. Orbital Express Overview
Orbital Express (OE) Demonstration System is to demonstrate the operational utility, cost effectiveness, and technical feasibility of autonomous techniques for on-orbit satellite servicing
The specific objectives of OE are to develop and demonstrate on orbit:
An autonomous guidance, navigation, and control system
Autonomous rendezvous, proximity operations, and capture
Orbit fluid transfer between a depot/serviceable satellite and a servicing satellite
Component transfer and verified operation of the component
A nonproprietary satellite servicing interface specification

3. OE Vehicles Introduction
ASTRO: Autonomous Space Transfer and Robotic Orbiter
Servicing satellite
NEXTSat/CSC: Next Generation Satellite/Commodity Spacecraft
Functions as the satellite being serviced by ASTRO and as a supply depot for ASTRO

4. Orbital Express Vehicles
ASTRO (Servicer)
NEXTSat (Client)
Capture (Docking) & Fluid Transfer
Interfaces
Robotic Arm
14 April 2006
1 Dec. 2005

5. ASTRO Servicing Vehicle
AC-3 ORU
Battery ORU
Container
Container
Battery
FTAPS Fill and Drain
Manipulator Arm
GPS Antenna- #2
TDRSS Antenna- #2
CrossLink Antenna
SGLS Antenna- #2
Boeing
Spacecraft Separation Ring
MDR
Thrusters X Z Y
Starsys
Fluid Coupler
NGST
Active Capture System
BATC

6. NEXTSat Client/Commodities Vehicle
Sensor Targets
Capture Mechanism
FTS
Vis-Star Target
Probe Fixture Assy
Sep System I/F Ring
Crosslink
ORU Interface Assy

7. Major Mission Objectives
On-Orbit demonstration of technologies required to support autonomous on-orbit servicing of satellites
Perform autonomous fluid transfer
Transfer of propellant in a 0-g environment
Perform autonomous ORU transfer
Component replacement
Battery Transfer
Computer Transfer
Perform autonomous rendezvous and capture of a client satellite
Direct Capture
Free-Flyer Capture

8. Mission Plan Mission Duration: ~90 days
Certified Spacecraft Life: 1 year
Mission Phases:
Launch & Activation
Checkouts
Core bus subsystems
Servicing subsystems
Robotic Arm, Capture, Fluid Transfer
Advanced Technology Demonstrations
Execution of 8 Scenarios

9. Mission Timeline

10. OE Launch from Cape Canaveral
Orbit: 492-km circular 46-deg inclination
ASTRO
Dimensions: 69”x70”, span 220”
Power: watts
On-orbit fueled weight: ~2,400 lb
NEXTSat:
Dimensions: 38.7in long
Power: 500 watts
Mass: 500 lbs (224 kg)
March 8, 2007
OE Launch from Cape Canaveral

11. Autonomous Operations
Autonomous Mission Manager
Implements operations requirements by using sequences and related information in a database
Ability to plan missions dynamically
Command subsystems within the vehicle management system
Monitor systems and diagnose their failures
Database executed fully autonomously, but with high level of input from ground team into database creation
Controls starting, interruption, managing Authority-To-Proceeds, aborting of sequences; and enables human supervision of the sequences running autonomously
Executive Sequencer
Monitor
Contingency Responder
Resource Predictor/Ground Communicator
Autonomous mission controllers use man-machine collaborative autonomy, which allows systems to be implemented with variable levels of autonomy
Ground Segment
Assemble and verify sequences for upload
Displays status of Mission Manager and next planned event

12. Fluid Transfers
The Northrop Grumman-provided hardware demonstrates autonomous transfer of hydrazine propellant, a type of liquid rocket fuel, to and from the NextSat spacecraft, in addition to providing the propulsion needed for six-degree-of-freedom vehicle control.
Multiple types of fluid transfers are demonstrated
Total of 24 tests are planned
6 at lowest level of autonomy
5 at middle level of autonomy
24 at highest level of autonomy
Demonstration plan sets a foundation for the operational system
Transfer from commodity station simulated
Transfer to client satellite simulated
Capability leads to the autonomous replenishment of fuel to existing satellites, allowing more flexibility and extension of life
End-to-End Test

13. Orbital Express Demonstration Manipulator System
MDA developed the Orbital Express Autonomous Robotic Manipulator System comprising the following space and ground elements:
Small next generation Robotic arm on ASTRO with avionics and autonomous vision system
Grapple fixtures and vision target for Free-Flyer Capture and ORU transfer
Mating interface camera and lighting system
Standard, non-proprietary ORU containers and mating interfaces
Proximity-Ops lighting system
Autonomous Software
Robotic Ground Segment
Length 3m
Mass
71kg
Volume
65cm x 49cm x 186cm
Power
131 watts
DOF 6
Manipulator Arm
Specifics

14. Orbital Express Demonstration Manipulator System Functions
Autonomous Free-Flyer Capture of Client Satellite
Robotic Arm on ASTRO will drive autonomously using highly-reliable vision feedback from a camera at its tip to capture NEXTSat
Autonomous Positioning of Client Satellite for Mating
Following capture, the Arm will position the client satellite at the mating interface between the spacecraft, allowing the ASTRO Capture System to close around NEXTSat
Autonomous Video Survey of Client Spacecraft
Robotic System will be used to perform a visual inspection of the spacecraft for spacecraft status and situational awareness
Sites for video inspection include deployment mechanisms, antennae, ORU mating interfaces, cameras, and solar arrays
Autonomous ORU Transfer
The standard ORU container may contain batteries, a new flight computer, science instruments, or any other replaceable component
OE Robotic System will demonstrate transfer of a battery and a replacement flight computer to and from the client satellite
Autonomy
OE has been designed to operate under four levels of supervised autonomy, and will demonstrate servicing operations under each increasingly challenging level

15. ORU Transfers ORU = Orbital Replacement Unit
ORU can be a science instrument, a subsystem component, or a heat shield; anything that is replaceable on-orbit
Standard interfaces for all ORUs
Boeing: ASTRO interface
Ball: NEXTSat interface
MDA: ORU interface
Transfer two types of components
Batteries often limit life of satellites
Computers become obsolete in a short time
Demonstration plan sets a foundation for the operational system
Total of 11 transfers planned
1 at lowest autonomy, 2 at middle, and 8 at highest level of autonomy
Transfer from commodity station simulated
Transfer to client satellite simulated
ORU

16. Unmated Operations Autonomous Guidance, Navigation, & Control
Fully-autonomous guidance software performs demate, separation, departure, rendezvous, proximity operations, and capture
Fully-autonomous attitude software points vehicle in require directions during each segment of approach and separation
Onboard guidance sequencer progresses through translation and pointing modes during approach and separation
Functionally-redundant rendezvous sensors track target from over 200 km to capture
Fully-autonomous navigation filters sort and weight data from multiple sources
GN&C performs internal sanity checks and executes rendezvous abort if thresholds exceeded
OE Rendezvous GN&C system is capable of autonomous rendezvous from 200 km to capture

17. Unmated Operations Autonomous Rendezvous & Capture Sensor Suite
Provides real-time, critical relative state information about the client satellite seamlessly across the entire mission scenario
Patented Vis-STAR tracking algorithm provides robust tracking from point source to capture
Algorithms are nearly sensor independent
Mission reliability is enhanced through redundant sensors which can operate across a broad range of viewing conditions (in various lighting conditions, with clear space and cluttered earth backgrounds)
NFOV and WFOV visible sensors covering ranges from zero meters to hundreds of kilometers
An infrared sensor for viewing even in complete darkness
An independent laser-based imaging tracker activates during final approach and capture operations

18. Free-Flyer Capture
Robotic Arm on ASTRO will drive autonomously using highly-reliable vision feedback from a camera at its tip to capture NEXTSat
Berthing requires the advanced robotic arm to
grapple NEXTSat from a distance of 1.5 m and
position it within the capture envelope

19. Orbital Express Capture System
Subsystems support two critical functions
Shock-less separation of the two OE spacecraft after launch
Capture and mating of the spacecraft prior to servicing
Starsys designed and delivered the capture and mating system for the Orbital Express spacecraft
Capture and mating system extends from the servicing spacecraft and grasps the client spacecraft
Duration = 10 sec
Tolerance in satellite positioning is a 5.1-in.-long and 5.5-in.-dia. cylinder
Then retracts creating a structurally robust connection between the two craft that allows for fluid and electrical connections, and component replacement

20. Current Mission Status
Launch & Early Activation checkouts complete
FTS Activation in prep for 1st fluid transfer
ARCSS checkouts
OEDMS deployed!
OEDMS Video Recording
Complete OEDMS Checkouts
Prep for first scenario next week

21. Summary
Orbital Express is demonstrating the technologies required for on-orbit servicing
Currently orbiting test bed for potential servicing scenarios
Plenty of spacecraft life after baseline mission is complete
Potential VIP visit for FISO members to KAFB for a servicing scenario