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Large and fragile space structures such as telescopes and solar sails demand robotic manipulators that combine adaptability with safe interaction. Conventional rigid manipulators lack compliance, while existing continuum robots struggle with controllability and are limited to single‐curvature deformation. Here, a bioinspired tensegrity‐based continuum robot with programmable stiffness is introduced that achieves adaptive multicurvature morphing through intra‐ and intermodule stiffness distribution. A unified energy‐based framework establishes self‐equilibrium and predictive deformation of serial tensegrity modules, enabling systematic design and control. The approach is validated through computational modeling and physical experiments, demonstrating geometry‐specific adaptation to hexagonal, circular, elliptical, and polygonal profiles relevant to on‐orbit assembly. The designed six‐module BTCR prototype achieves at least twofold differences in segmental curvature and bending angle through stiffness distribution, with theoretical maximum values of 230° bending angle and 8 m−1 curvature. Stiffness programming reduces reliance on continuous actuation while expanding accessible deformation modes, offering a lightweight and reconfigurable pathway for safe manipulation of fragile structures. This work advances continuum robotics by merging tensegrity mechanics with stiffness‐programmable design, with broad implications for space assembly, deployable systems, and adaptive manipulation in extreme environments. A bioinspired tensegrity‐based continuum robot (BTCR) with programmable stiffness enables adaptive multicurvature morphing via coordinated intra‐ and intermodule regulation. A unified energy‐based framework predicts self‐equilibrium and deformation for serial modules. Experiments and Simulations demonstrate reconfiguration into hexagonal, circular, and polygonal shapes, reducing actuation demands while improving reconfigurability for lightweight, safe manipulation of fragile space structures.

Considering the complexity of on-orbit assembly during space missions and the super-large size of space structures, this paper presents the design for a new type of docking interface with an androgynous body that exhibits a number of advantages, including high connection strength and a compact structure. The androgynous body has a conical guided symmetric design with a symmetry of 90°. The geometric design of the docking surface is described in detail in order to prove its advantages. Structural design was carried out using UG modeling as well as dynamic simulation using Recur Dyn to obtain the displacement coordinate curves of the docking port. The geometry of the docking port’s high docking misalignment tolerance was verified, and misalignment tolerance and lens splicing experiments were also performed. The docking port’s ability to be quickly connected or disconnected within a translation tolerance of 23.5 mm and a tilt tolerance of 24° was verified. This article provides a useful reference for space missions in terms of module docking and on-orbit assembly.

Currently, the passive part of the space station platform’s docking device has been finalized, emphasizing the need for a docking mechanism that enables the on-orbit assembly of large payloads using in-situ resources. This paper presents the design of a compact, high-precision dual-component docking mechanism for large space loads. First, we propose a parametric design for the active and passive sides, accompanied by the constraint equations for the capture mechanism. Next, a progressive positioning method, beginning with coarse correction and followed by fine correction, is proposed. The dual-component calibration and positioning performance are analyzed to initially capture large deviations and achieve high-accuracy docking of electrical and hydraulic connectors subsequently. Static analysis of both single and dual components reveals a positive correlation between load-carrying capacity and diameter. During the prototype testing, the maximum positional deviations were measured 0.12 mm in the X -direction, 0.5 mm in the Y -direction, and 0.07 mm in the Z -direction. The maximum angular deviation was 0.04° when the dual components operated together. Finally, the impact of axial and radial docking conditions in orbit was analyzed to verify that the loading requirements were satisfied. This work offers both theoretical and technical insights for the future development of docking mechanisms for large space loads.

With the accelerated pace of human space exploration and the progress of other related researches, there is an increasingly urgent demand for space infrastructure, equipment, and diversified spacecraft construction for space missions, and how to efficiently, intelligently, and autonomously build corresponding facilities and equipment on orbit according to the functional requirements of different missions has become a great challenge in the field of space technology research. As an important means of automated manufacturing, the construction of on-orbit assembly systems centered on space robotics has become an emerging development trend. In view of its importance, space agencies and research institutes have successively proposed and developed a series of related programs. In order to comprehensively understand the progress of on-orbit assembly with space robots (OASR) and scientific problems involved, this paper investigates the current status of research and technological development in OASR. Firstly, the significance of OASR for space exploration and other space missions is analyzed. Secondly, the existing classification forms of on-orbit assembly are outlined and a classification idea is proposed from the point of view of the combination of space robot motion capability and assembly goals. Thirdly, the research and development status of OASR in the United States, Europe, Canada, Japan, and China is investigated. Then, based on a review of the literature on space robots to realize on-orbit assembly in space facilities, some of the key technologies involved are reviewed and discussed. Finally, this paper discusses and looks ahead to the future development trend and application prospect of the technology of OASR, reveals and explains the crucial position it occupies as well as the important role it can play in the process of human space exploration, and is expected to provide useful references for the in-depth research and development of future on-orbit assembly technology.

To meet the increasing communication demands, the satellites need to be equipped with the high-accuracy and large-aperture antennas. One of the effective methods to construct the modular antennas with ultra-high accuracy and ultra-large aperture is on-orbit assembly technology. During the on-orbit assembly missions, the assembly error is a key factor to affect the surface accuracy of the modular antennas. This paper studies the node design of each module and the assembly error analysis of the modular antennas. A design method of the module nodes is presented with consideration of the assembly gap between two modules. Meanwhile, a soft connection mechanism is designed to ensure the mobility among the assembly modules. To investigate the transmission law of the assembly errors, an analytical model of assembly error is derived based on the exponential product method. In order to establish the deformation surface with rotation and displacement assembly errors, an error ball concept is proposed by the analytical model. To decrease the assembly errors, the actuators are installed among some modules. Moreover, an adjustment method is proposed to obtain the adjustment amounts of actuators. Finally, the correctness of analytical model and the effectiveness of the adjustment method are demonstrated by the numerical simulations.

Ultra-large structures serve as core aerospace equipment for missions such as Earth observation and deep space exploration. With dimensions reaching hundreds of meters or even kilometers, they require advanced technologies, including on-orbit assembly, modular integration, and robot-assisted construction, to achieve high-precision structural formation and stable operation. For on-orbit assembly of these structures, critical attention must be paid to their inherent vibration characteristics to evaluate on-orbit service stiffness and stability. Additionally, the static deformation behavior during assembly must be examined to assess the impact of assembly loads on overall structural deformation and surface accuracy. To efficiently evaluate the above-mentioned characteristics, an equivalent scale analysis method for the on-orbit assembly of space-based megastructures is established. Through theoretical modelling, it establishes scaling relationships between mechanical properties-such as structural natural vibration and static deformation-and module diameter dimensions. The numerical results indicate that halving the module diameter results in the natural frequency of the assembled structure increasing by about four times and the static deformation decreasing by about eight times, in agreement with the scaling law. This method enables accurate inference of the full-scale structure's on-orbit mechanical behavior, thereby facilitating precise evaluation of typical mechanical characteristics during ultra-large structure on-orbit assembly.

A servicing spacecraft motion control approach for the problem of on-orbit truss structure assembly is developed in this paper. It is considered that a cargo container with a rod set and servicing spacecraft are in orbit initially. The assembly procedure is based on spacecraft free-flight motion between the structure’s specified points. The spacecraft is equipped with two robotic manipulators capable of attaching to the structure and holding rods. In addition, the spacecraft can repulse from the structure with a given relative velocity using a manipulator, so the spacecraft and the structure receive impulses. The repulsion velocity vector is calculated in order to reach the structure target point to deliver and install the rod into the truss structure, or to reach the cargo container and take a rod. The problem of searching the repulsion velocity is formulated as an optimization problem with constraints, taking into account the limited value of the repulsion velocity, collision avoidance with structure, restrictions on the angular velocity and translational motion of the structure in the orbital reference frame. This problem is solved numerically with an initial guess vector obtained analytically for simplified motion cases. The application of the proposed control scheme to the assembly of a truss-based antenna is demonstrated. It is shown that the servicing spacecraft is successfully transferred between the structure points by means of manipulator repulsion. Main features and limitations of the assembly problem using a spacecraft with two manipulators are discussed.

Purpose On-orbit assembly technology is a promising research topic in spaceflight field. For purposes of studying the dynamic performance and reducing weight of an on-orbit assembly satellite structure frame, this paper aims to propose a structural optimization design method based on natural frequency. Design/methodology/approach The dynamic stability of the satellite under working condition depends on the mechanical properties of the structure matrix. A global structural optimization model is established, with the objective of mass minimization and the constraints of given natural frequencies and given structure requirements. The structural optimization and improvement design method is proposed using sequential quadratic programming calculation. Findings The optimal result of objective function is effectively obtained, and the best combination of structural geometric parameters is configurated. By analyzing the relationship between the structural variables and optimization parameters, the primary and secondary factors to the mass optimization process of the microsatellite satisfying the dynamic performance requirements are obtained, which improves the effectiveness and accuracy of the system optimization design. Originality/value This method can coordinate the relation between satellite vibration stability and weight reduction, which provides an effective way for the optimization design of on-orbit assembly microsatellite. It has reference significance for the similar spacecraft framework structure design.

The on-orbit operation of insertion and extraction of space robots is a technology essential to the assembly and maintenance in orbit, satellite fuel filling, failed satellite recovery, especially modular in-orbit assembly of micro-spacecraft. Therefore, the force/posture impedance control for the on-orbit operation of insertion and extraction is studied. Firstly, the dynamic model of space robots’ system in the form of uncontrolled carrier position and controlled attitude is derived by using the momentum conservation principle. Through the kinematic constraints of the replacement component plug, the Jacobi relationship of the plug motion in the base coordinate system is established. Secondly, to achieve the output force control of the plug during the on-orbit operation of insertion and extraction, a second-order linear impedance model is established based on the dynamic relationship between the plug posture and its output force and the impedance control principle. Then, in order to improve the stability, robustness, and adaptability of the controller, an adaptive Radial Basis Function Neural Network (RBFNN) is used to approximate the uncertainties in the dynamic model for the force/posture control of the plug. Finally, the stability of the system is verified by the Lyapunov principle. The simulation results show that the designed neural network impedance control strategy can achieve a control accuracy of less than 10−3 rad for the plug’s attitude tracking error, less than 10−3 m for its position tracking error, and less than 0.5 N for its output force tracking error.

In response to the requirements of large-scale space in-orbit assembly and the special environment of low gravity in space, this paper proposes a small robot structure with the integration of assembly, connection, and vibration reduction functionalities. Each robot consists of a body and three composite mechanical arms-legs, which can dock and transfer assembly units with the transport spacecraft unit, and also crawl along the edge truss of the assembly unit to a designated location to complete in-orbit assembly while ensuring precision. A theoretical model of robot motion was established for simulation studies, and in the research process, the vibration of the assembly unit was studied, and preliminary adjustments were made to address the vibration issue. The results show that this structure is feasible for in-orbit assembly schemes and has good adjustment ability for flexible vibration.