Integration and calibration of an in situ robotic manufacturing system for high-precision machining of large-span spacecraft brackets with associated datum

Abstract

In this research, a robotic in situ manufacturing system based on the integration of measurement and machining technology is developed to address the challenge of achieving high precision and efficiency in the manufacturing of spacecraft brackets in large-scale scenarios. First, a robotic in-situ manufacturing system is established, that integrates globally unified measurement data, high-precision conversion of machining datums, and closed-loop control of end machining processes. A multiparameter optimal fitting calibration method is subsequently employed to calibrate several key parameters of the end-effector within the integrated measurement and machining process, ensuring the initial geometric accuracy of the manufacturing system. The experimental results indicate that within a 2-meter range, the average absolute error is 0.024 mm, with both the standard deviation and root mean square error not exceeding 0.038 mm. The overall system has an average error of 0.083 mm and a maximum error of 0.096 mm. Additionally, experiments are conducted in a laboratory setting simulating the manufacturing of large-span datum-associated spacecraft brackets, validating the high precision and effectiveness of the in situ robotic manufacturing system.