Intelligent production line with an annual output of 240 satellites can also be "privately customized"
In recent years, the large-scale low-orbit broadband satellite constellation project represented by the "Starlink" constellation of SpaceX in the United States has overturned people's understanding of the traditional satellite production model.
The satellite intelligent manufacturing production line has become a new development direction for satellite research and development.
The reporter learned from the Space Engineering Company of the Second Academy of China Aerospace Science and Industry Corporation that my country’s first batch-produced satellite intelligent production line developed by the company has recently completed the design, production and installation work and has officially entered the on-site trial operation stage.
Its designed capacity target is to produce more than 240 small satellites per year, and can realize mass customization production.
From manual manufacturing to automated "intelligent manufacturing"
"Satellites need to go through more than ten processes from the raw materials out of the warehouse to the qualified inspection of the entire satellite, and more than ten processes such as deck-level assembly, satellite assembly, and overall satellite electrical performance testing." Liu Feng, leader of the commando team, a member of the Intelligent Manufacturing Star of Space Engineering Said that if all the key process links are replaced by machines, production efficiency can be increased by more than 40%.
However, it is not so easy to go from single-piece and small-batch manual manufacturing to highly automated "intelligent manufacturing".
Satellites are typical complex electromechanical products with many assembly processes and complex technological processes. The integration and compatibility of processes must also be considered.
Batch production process planning is the first problem to be solved.
In order to transform the traditional manual production mode of satellites into a lean, automated, and collaborative assembly-line production mode, the developers have thoroughly understood every process and technological process in the traditional assembly process, optimized one by one, and then optimized The subsequent processes are connected in series to form a complete new batch production process flow. Since then, analysis and optimization have been carried out many times.
Commando Mach said that after multiple rounds of program iterations, the final process can ensure the design capacity target of more than 240 small satellites per year while ensuring that the satellite assembly and testing process meets the technical requirements.
Can be batch produced or customized
While achieving batch production, the production line can also achieve "private customization."
The configuration, size and weight of satellites of different models and specifications are quite different.
In order to make the "hard state" equipment "not reject" satellites, the developers used precision motion mechanisms to equip the equipment with "limbs". The size of the workstation is also dynamically adjustable, and parts of different sizes and weights are flexibly clamped. And high-precision assembly is not a problem.
During the production process, the equipment will determine the satellite type and process requirements based on the barcode, autonomously call the control program, and the data analysis and execution results will also be fed back to the production line control terminal in real time.
Not only has the production process been transformed from human-driven to data-driven, it also makes satellite mass customization production a reality.
In order to improve the intelligence of the production line, the developers have carried out a number of technical research.
The final assembly is a crucial link in satellite production.
In view of the lack of automatic sensing ability in the assembly station of the department and the inability to effectively detect and avoid the collision of parts and components during the assembly process, the developers added force sensors to the manipulator and end effector to ensure that the parts and the deck are not in the process of installation. Squeezing will occur; and during the assembly process, the camera is used to take pictures of the interference risk area, and the collision risk is detected in advance through image comparison.
In addition, the camera's vision compensation can also improve the positioning accuracy of the assembly.
Successful trial operation is an important node in the construction of the production line.
At present, the commando team of Smart Star Party members is fully engaged in trial operation, contributing to the early formation of large-scale satellite intelligent production capabilities.