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MOSAR: Demonstration of Modular Spacecraft Assembly and Reconfiguration

Conference Paper · October 2021

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 MOSAR: Demonstration of Modular Spacecraft Assembly and Reconfiguration

Pierre Letiera*, Mathieu Deremetza, Gerhard Grunwaldb, Jose Miguel Sanchez Martinezc, Matthew
Rowlingsd, Pablo Lopez Negroe, Daniele Filippettof, Juan Sanchez Garcia Casarrubiosg, Xiu-Tian Yanh, Pierre
Dissaux
a
Space Applications Services NV/SA, Leuvensesteenweg 325, 1932 Sint-Stevens-Woluwe (Brussels Area), Belgium,
firstname.lastname@spaceapplications.com
b
Institute of Robotics and Mechatronics, German Aerospace Center (DLR), Gerhard.Grunwald@dlr.de
c
GMV Aerospace & Defence SAU, Spain, Spain, jomsanchez@gmv.com
d
Thales Alenia Space, United Kingdom, matthew.rowlings@thalesaleniaspace.com
e
Thales Alenia Space France, pablo.lopez-negro@thalesaleniaspace.com
f
Sitael Spa, Italy, daniele.lippetto@sitael.com
g
MAG SOAR, Spain, jsanchez@magsoar.com
h
University of Strathclyde, United Kingdom, x.yan@strath.ac.uk
Ellidiss, France, pierre.dissaux@ellidiss.com
* Corresponding Author

Abstract

The concept of modular and reconfigurable spacecraft is a possible game-changer solution to answer the future
challenges of the space industry and exploration, that includes, space sustainability, economical profitability, system
reliability and large structure on-orbit assemblies. This concept will be enabled by and is strongly associated with the
development of autonomous robotic solutions, re-usable components and standardization of designs. This will lead to
the emergence of more affordable and reliable components, also opening new possibilities for future space missions,
such as life-time extension or missions reconfigurations.
The main objective of the EC project MOSAR, part of the EU Strategic Research Cluster in Space Robotics, is to
elaborate and refine the concept of modular and reconfigurable spacecraft in the context of on-orbit servicing and
assembly. This is achieved by the development of a ground demonstrator of on-orbit modular satellite
reconfiguration, and by the analysis and elicitation of recommendations for the exploitation and maturation of the
associated technologies.
The MOSAR demonstrator aims at illustrating the servicing mission of a modular client satellite, from the initial
mission design to the assembly and reconfiguration operations. Several technologies have been developed and
integrated in this demonstrator that include, re-usable spacecraft modules, a walking robotic manipulator arm,
HOTDOCK standard mating connectors, and a Functional engineering simulation environment.
In addition, the demonstrator relies on the upgrade of robotics software and hardware building blocks
components developed previously in the same research cluster, for autonomous planning or module data
management. Different scenarios, illustrating modular spacecraft concepts have been demonstrated, as assembly and
reconfiguration of the client satellite, automatic data and power network reconfiguration, thermal management
between modules, software reconfiguration and external visual detection.
The purpose of this paper is to present the outcomes of the MOSAR project, focusing on the results of the
demonstration scenarios and the perspective of technologies exploitation and maturation.

Keywords: Space robotics, On-orbit Servicing, Modular Spacecraft, Relocatable Manipulator, Standard
Interconnects, Thermal Management,

Acronyms/Abbreviations Cluster (SRC), Service Spacecraft (SVC), Technology

Readiness Level (TRL), Walking Manipulator (WM)
Client Satellite (CLT), Data Function Nodes (DFN),
Degrees of Freedom (DOF), Functional Engineering
Simulator (FES), Instrument Control Unit (ICU),
Monitoring and Control Center (MCC), On-Board
Computer (OBC), Operational Grants (OG), Remote
Memory Access Protocol (RMAP), Spacecraft Modules
(SM), Standard Interconnector (SI), Strategic Research

Page 1 of 13
1. Introduction demonstration are summarized, before the conclusion
with a focus on the impact of MOSAR for further
A major trend in space is the emergence of on-orbit
activities.
servicing, maintenance, refueling and lifetime extension
capabilities [1], which have been demonstrated by
companies in North America, as for example with the
recent re-fueling operation performed by Northrop
Grumman’s MEV-1 servicer [2]. A further trend is the
huge investments made by NASA to promote the
commercialization of low Earth orbit space assets,
which will continue with the development of
commercial space stations and platforms. The interest
for space sustainability is also growing very fast, with
the main focus on the removal of the space debris and
satellite end-of-life management, as illustrated by the
ESA Clean Space initiative [3] and the mission
CLearSpace-1, planned for 2025 [4], targeting the first
debris removal from orbit.
Offering cost effective, performant, reliable, scalable Fig.1. Artist view of the MOSAR concept
and flexible solutions will be essential to make the
European space industry spearheading strategic 2. Project Overview
segments of the commercial space. The development of 2.1 MOSAR Mission Overview
novel, European technologies that would allow
standardizing satellites components, facilitating their The technologies developed in MOSAR aim to
assembly, reducing time between customer’s orders and support the development of fully modular and on-orbit
commissioning in space, repairing and upgrading reconfigurable spacecraft. This ambitious objective is
components directly in orbit instead of replacing derived into a demonstrative mission concept that
entirely a failed or damaged satellite, would provide allows the deployment of MOSAR technologies in the
extremely valuable competitive edges to establish near/middle future. A general introductive video is
European leadership in a number of key commercial provided in [5]. Fig 1. shows an artistic view,
space segments. illustrating the MOSAR concept, as described below.
MOSAR is a space sustainability oriented research The proposed demonstrative mission concept and
project of the European Commission proposing a new spacecraft design are represented in Fig. 2. The baseline
paradigm for the on-orbit assembly, operations and scenario is the one of a Servicer Spacecraft (SVC)
servicing of spacecraft. With a consortium of nine transporting a cargo of Spacecraft Modules (SM) and a
industrial and academic partners, MOSAR shall dedicated Walking Manipulator (WM). This last enables
elaborate and refine the concept of Modular Spacecraft, a number of operations with the transfer of SM from
identify and recommend standards and design the and to the Client Spacecraft (CLT), with the purpose of
ground and space infrastructure elements that will adding, replacing or enhancing client platform or
enable its realization and sustain its progressive payload functionalities.
deployment and economical exploitation. MOSAR is
part of the European Space Robotic Technologies
Strategic Research Cluster (SRC), aiming at enabling
major advances in strategic key points of Space
Robotics Technologies, in order to improve the
European competitiveness in space robotics
technologies [6].
The project has been recently finalized with the
performance of the final demonstration. This paper
provides a general overview of the activities and
highlights key results. The first section introduces the
general concept proposed by MOSAR and describes the
principal objectives of the activity. Then, the main Fig.2. Spacecraft design MOSAR-like mission (client
technologies developed and matured during the project and servicer)
are described. Following that, the results of the different

Page 2 of 13
 This mission concept aims at making use of
MOSAR technologies to introduce enhanced
functionalities on space missions, mainly on two topics:
 Standardization of design thanks to modularity
approach: a common design of the product line
allows multiple configurations to meet different
mission objectives thanks to the standardized
interfaces that could be used to plug additional
payloads and service modules. In this way, the
customization needed to meet specific mission
objectives does not need a redesign of the main
elements of the spacecraft.
 The spacecraft, equipped with multiple standard
interfaces and some modules, performs its original
missions for some years with the option of
introducing new elements or reconfiguring the
mission by replacing or adding new modules
brought by a servicer satellite equipped with a
robotic manipulator.
The client satellite is built around a standardized
common platform, with all the required main
functionalities. The platform is designed to cover an
envelope of payloads and functions. It can be initially
specialized, on-ground, with a primary payload and
services modules. Both the platform and the payload
are equipped with standard interfaces enabling the
connection of the standard modules, for initial
configuration on-ground or for addition or replacement
of units during on-orbit mission.
Spacecraft Modules are individual structures
associated with a specific function of the spacecraft, that
once assembled, will ensure the spacecraft operations.
They can cover system or payload functions. The SM
are equipped with SI, enabling Modules to Modules and
Modules to spacecraft connections. Each SI provides
mechanical, data, power and thermal transfer
capabilities, allowing a full configuration of the CLT
functions. That includes mechanical structural integrity,
data transmission, power routing and thermal
management along the elements.
The autonomous transfer and configuration of the
SM follow an execution plan prepared and validated
off-line, in the Monitoring and Control Centre (MCC),
on the ground segment. The MCC includes a satellite
design, modelling and validation tool, specifically
targeting modular satellites applications. It also allows
the automatic planning of the assembly or
reconfiguration sequence that can be verified with a
multi-physics simulator (FES). All these elements are
working iteratively together to prepare a valid execution
plan that is finally uploaded to the spacecraft for
execution. Based on the monitoring and feedback
information received from the spacecraft during the
operations (e.g. detected failed module), the MCC can
update the execution plan. The MCC finally includes
visualisation front-end to support the design,
verification and monitoring activities during sequence
execution.
2.2 MOSAR Project Objectives
The first main objective of MOSAR is to develop
and mature key technologies and product ecosystem that
will support in the future the deployment and operations
of modular spacecraft:
 Extension and integration of the ESROCOS, ERGO,
INFUSE, I3DS and HOTDOCK common building
blocks, the outcomes from the previous Operational
Grants (OG), belonging to the same European
Research Cluster. The aim is to encourage
reusability, and initiate the standardization in the
European space robotic endeavour.
 Development of a repositionable robotic
manipulation (aka. Walking Manipulator, WM)
system allowing the manipulation and relocation of
the Spacecraft Modules
 Development of a modular Spacecraft Modules
ecosystem, consisting of
o Standardized functional modules;
o Suitable power and data buses technologies
allowing flexible and hot-reconfiguration;
o Functional Engineering Simulation (FES)
environment offering assistance for the design
of modular satellites, for the verification of
obtained designs (multi-physics simulation),
and for the motion planning and rehearsal of
assembly / reconfiguration operations.
The second main objective of MOSAR is to develop
a sound technology ground demonstrator of on-orbit
modular satellite reconfiguration relying on robotic
capabilities, exploiting the technologies described above,
in order to illustrate the operative mission described in
the previous section.
2.3 From Mission to Demonstration
MOSAR demonstrator aims at reproducing the main
functionalities needed for on-orbit module assembly and
reconfiguration of spacecraft, as described in the
mission section above. Fig. 3 illustrates the concept for
the spatial mission, involving a client and a servicer
satellite, already docked. From this concept, a physical
ground demonstrator has been integrated, including
representative components for the servicer and client
spacecraft buses, several functional modules, some of
them being already installed on the client, and other
ones brought by the servicer, and the walking
manipulator. The MOSAR ground demonstrator has
been built in order to provide the most realistic vision
Page 3 of 13
compared to the proposed space design approach. It had
however to take into account practical constraints,
mainly imposed by the presence of the gravity, reducing
the capability to perform modular operations with big
assets. The nominal module size in the demonstrator has
been selected in accordance to the 1U size unit, in order
to limit the modules weight to the lifting capabilities of
the Walking Manipulator. The operational concept is
however fully extendable to other shape, sizes and
structures of elements.
The ground demonstrator has been focusing on the
validation of the sequence of operations needed for the
preparation of the operations with the ground support
tools (design, simulation and planning), the operational
concept of manipulator and spacecraft module
relocation, resources re-allocation and further client
satellite operations. It addresses the following topics:
 Hardware: with the possibility to re-configure the
physical arrangement of the spacecraft and/or
providing means to add/replace/upgrade specific
functions.
 Software: with the possibility to re-configure
components responsibilities and support the re-
configuration operations
 Data: with the possibility to re-route TM/TC and
data transmission along the different elements
 Power: with the possibility to re-route and control
the power transmission along the elements.
 Thermal: possibility to manage thermal loads, to
increase dissipation capabilities or maintain thermal
stability of modules.
 Visual: possibility to support operations through
external visual detection system, targeting the
Fig.3. MOSAR Ground Demonstrator derivate from MOSAR mission concept
inspection of spacecraft configuration and detection
of anomalies.
In parallel to this integration, two other setups have
been developed for the demonstration of the thermal
module management and the external visual detection
system. They will be described in the corresponding
section, about the demonstration results.
3. MOSAR Technologies
3.1 ESROCOS
The ESROCOS framework provides a set of tools
and reusable runtime components for the development
of robot control software [7]. The ESROCOS
framework has been implemented in MOSAR as the
central component for the development of the system
control software. The main application of ESROCOS
during MOSAR project was to develop a model of all
the software instances needed for the described
scenarios. This model includes all the functions and
interfaces between all the main components needed
which are the Ground, Servicer and Client partitions.
During MOSAR project new ESROCOS
components have been created and some others have
been updated to be used in the final software version
that manages the full system including the MCC, Client
and Servicer (Fig. 4). Main extension and update cover
the PUS Services library and PUS console to support
multi-instance operations, and the SpW driver for the
management of all sub-systems via RMAP. The aspects
related to software reconfiguration have also been
analysed and demonstrated on simple scenarios. The
work on ESROCOS during MOSAR provided the
opportunity to improve the use and implementation of
the software, in the context of its re-usability for the
next PERASPERA call and other projects.
Page 4 of 13

Fig.4. On-Board software ESROCOS model
3.2 ERGO
The ERGO framework provides a set of tools and
components to develop an autonomy control system for
robots [8]. It is easily configurable and tailorable to the
specific use case, and contains tools from a high level
planning point of view to the low level control of certain
systems such as a robotic arm.
The role of ERGO within the MOSAR system is to
compute a plan for the robotic and software
reconfiguration in the demonstration scenarios, and
manage its execution against the simulator or the real
scenario, with the control of the manipulator and the
HOTDOCK SI. During the MOSAR project, some of
the tools from ERGO were used without the need of any
change, while others needed some adaptation /
extension or configuration. This includes four
components that are the PUS Ground Control Interface
Reactor, the Mission Planner Reactor, Mission
decomposition Reactor and the Robotic Arm Motion
Planner. The configuration files defining the system
(timelines, reactors, PDDL, etc.) also had to be
developed during the project to configure the system to
the specific requirements.
Fig.5. ERGO planner architecture and virtual collision
computation
3.3 InFuse
InFuse is designed as both a software framework
and an open-source library for rapid development
solutions for sensor data fusion in order to provide a
good and timely understanding of the environment that
a robotic system such as MOSAR can perceive.
InFuse was mostly developed for planetary scenarios
during OG3-InFuse project even it has some functions
for on-orbit serving operations [9]. During MOSAR
research and investigation, a significant number of Data
Function Nodes (DFNs) have been created to extend the
capabilities of InFuse identified for MOSAR application.
These include eight DFNs for a range of operations
covering the stereo image filtering, disparity
enhancement and 3-D model reconstruction for object
detections. They also include all key functional nodes
for three types of anomaly detections identified for
MOSAR project.
Furthermore, three matching new DFCPs have also
been developed for surface anomaly detection,
identification of any interface anomalies, and detection
of any problems in configuration for modular satellites
during the constriction operations.
3.4 I3DS - Avionics
The I3DS platform (Integrated 3D sensors) is a
generic and modular system answering the needs of
near-future space exploration missions in terms of
exteroceptive and proprioceptive sensors with integrated
pre-processing and data concentration functions [10].
The key application of I3DS in MOSAR was to
develop the Instrument Control Unit (ICU) and the
sensor management abilities it provides, to a form that is
suitable for a modular spacecraft application. This
includes expanding the devices supported by the ICU to
include modular spacecraft components and refining the
ICU avionics networking aspects such that space-ready
technologies are used, whilst developing support of a
modular avionics network that can cope with dynamic
changes to the spacecraft's structure.
MOSAR implements a Reduced-ICU (R-ICU),
derived from the original I3DS ICU design and based
on the same ZU9EG Ultrascale+ platform from Xilinx.
It has been upgraded with a custom FMC that provides
the required SM interfaces for MOSAR. Validation of
the ICU Ultrascale+ MPSoC in a split real-time/Linux
configuration, this is a more realistic representative
application than demonstrated in I3DS. Validated use
when using only space-compatible interfaces
(SpaceWire, CAN). R-ICU + FMC concept validated to
make I3DS ICU tailored to mission requirements (e.g.
much more customisation to meet a mission mass,
power, cost budgets).
Page 5 of 13
 New features where developed for MOSAR R-ICU
that would also be compatible with the I3DS ICU,
including RMAP IP, Modular SW Framework for
Component Control, SpaceWire Network and Router,
RMAP TMTC Handler and SpaceWire Network
Discovery and PnP.
Fig.6. R-ICU hardware components, integrated in each
Spacecraft Module
3.5 HOTDOCK Standard Interconnects
HOTDOCK is an innovative standard mating device
for orbital and planetary space applications, supporting,
in a compact and integrated form factor, mechanical,
data, power and fluid transfer (Fig.7) [11]. In MOSAR,
it has been used:
 As the end-effector of the WM for the manipulation
of the spacecraft modules and to enable the motion
of the robot along the spacecraft, keeping powering
and data access;
 As interface on the module panels and spacecraft
structure for their interconnection, including
SpaceWire data and electrical power transmission,
through its central POGO pin board
 As key component for the test and validation of
thermal power transfer between two modules,
through the eight fluidic connectors.
Fig.7. Active and Passive HOTDOCK equipped with
fluidic interface
More than 30 units including active (with actuation
mechanism), passive (lighter version allowing data and
power transfer) and simple mechanical versions have
been integrated in the MOSAR setup. HOTDOCK
fulfilled the challenging requirements of the project. It
features high guidance capability through its external
from-fit geometry. This allows to operate the system
without visual feedback and relying only on position
and contact forces information. Its full 90 degrees
symmetric design (also for the electrical and fluidic
interfaces) provides independent module orientation
compatibility but also optimize the kinematic
configuration of the manipulator. Its high electrical
power and mechanical load capabilities support the
important constraints on the robot base and the full
power needs during operation.
3.6 Walking Manipulator
The Walking Manipulator [12], depicted in Fig. 8
and Fig. 9, is the central component and main actor of
the MOSAR’s concept. This 7-DOF robotic system is
performing the manipulation of the modules to
reconfigure the client spacecraft according to the
forwarded MCC’s plan. For this purpose, the Walking
Manipulator is also capable of relocating itself over the
spacecraft structure thanks to its end-effectors equipped
with HOTDOCK standard interconnects. This allows
the WM to reach further location than its nominal
workspace.
Fig.8. CAD overview of the Walking Manipulator
The WM offers a symmetric design to ensure a
uniform kinematics whatever its attachment point, and a
compact form factor to navigate between the spacecraft
modules. It also features a human like arm configuration
with asymmetric joints to increase its dexterity. The
overall length of the arm is 1.6 meters for a weight of
32kg. The WM provides up to 10kg payload lifting
capabilities at 1g in its entire workspace and is able to
lift itself in any configurations.
This robot embeds its own avionics: a robot control
unit, servo control units, communication interfaces and
Page 6 of 13
power and data buses. The WM can also be used to the on-ground demonstration in laboratory foreseen in
transfer power and data along its structure, through the MOSAR. Seven modules have then be produced and
HOTDOCK end-effectors. This allows to control equipped with HOTDOCK and payload to validate the
operations of an attached module during the assembly concept in the MOSAR demonstrator.
scenarios. The robotic joints are equipped with positon
and torque sensors to enable either position or
impedance control modes. Additional details on the
integration and specific validation of the WM are
described in [13].

Fig.10. 2U Spacecraft Module (space version design)

and 1U laboratory prototype (Battery module)
Proposed SM payloads covered a range of functions
including OBC, battery, camera payloads and thermal
management. Due to the high interest for space
applications, this last topic has been more deeply
investigated through the implementation of two
dedicated thermal modules, equipped with the new
thermal interface in HOTDOCK, with the purpose to
demonstrate close-loop operations of heat transfer. The
proposed design of the thermal modules offers the
advantages of symmetry, reliability, connection error-
free and zero leakage operations.

Fig.9. Walking Manipulator in the MOSAR ground

demonstrator
3.7 Modular and Repositionable Satellite Components
Within MOSAR project, the objective was to
demonstrate the capability of exploiting a modular
design in which each module is responsible of a
different system function taking the modularity
approach further with respect to the current satellites
design concepts. The Modular and Repositionable
Satellite Components were designed in order to provide
the mechanical framework able to host both the Fig.11. Thermal interface of HOTDOCK and integrated
HOTDOCK SI, and the specific subsystems units or thermal module demonstrator
payload, corresponding to the function required in the
3.8 Power and Data Buses Technologies
application. The result of the design consisted in the
standard structural frame of the modules (SMs) which SpaceWire networking was chosen for the MOSAR
includes the common elements of the primary structure, avionics due to its TRL9 status for flight use and its
such as the modules panels and the mechanical interface simplicity of networking (i.e. SpaceWire path and
to connect the HOTDOCK to the modules. logical addressing). Due to the dynamic nature of a
modular spacecraft's avionics network and the use of
With the target of standardization, scalability (for
potentially less reliable connections (intermediated SI
adaptation to different spacecraft classes), flexibility
compared to standard cable), between SMs, a dynamic
(catalogue of internal options), and based on a deep
networking capability is important for modular
analysis of MOSAR typical missions, the modules have
spacecraft. A Plug-and-Play TMTC set was developed
been first designed considering the space environment
based on the SPaceWire PnP draft standard. This allows
conditions, starting from the 1U module and then
the OBC to identify a SM, what connections are active
expanded to different shapes and sizes (up to 8U). The
and what components the SM supports. A discovery
design was then adapted to the specific environment of
algorithm was also developed for the OBC that can read

Page 7 of 13
the PnP TMTC and build a map of the SMs that are
connected and how they are connected together. A
routing algorithm is then be applied and uploaded to
each SM's SpW router using the relevant SpW PnP TCs.
Finally, a software SpW router was developed to
support the possible change of location of the nodes.
Remote Memory Access Protocol (RMAP) was
selected for the communication between ESROCOS and
R-ICU / WM OBC. The aim of the RMAP protocol is to
standardize the way in which SpaceWire units are
configured and to provide a flexible low-level
mechanism for the transfer of data between two
SpaceWire nodes.
The MOSAR power bus strategy has been developed
around the centralized Power Distribution Unit (cPDU),
located in each SM, the CLT and SVC, and controlled
by the local R-ICU through CAN bus. This component,
not anticipated at the beginning of the project and
specifically developed in MOSAR, has two main
purposes:
 Distribute the MOSAR 48V main bus between the
connected HOTDOCK power interfaces (e.g. on
different faces of SM), with the capability to
control the power transmission through a power
switch (up to 5 lines).
 Provides the required DC power for the internal
components of a module or spacecraft bus (SVC
and CLT), through DC/DC conversion from the
48V bus.
This strategy has proven to be viable for re-
configurable spacecraft, while providing a high level of
modularity and flexibility for the configuration of the
modules and their operations.
Fig.12. cPDU board for local SM power management
3.9 Functional Engineering Simulation Environment
In order to support the preparation of the
autonomous spacecraft reconfiguration operations, two
software tools have been developed, as part of the
MOSAR ecosystem.
The Spacecraft Design Tool provides a solution, to
the mission control team, to set up a scenario for
MOSAR, by specifying the initial and final state of a
scenario as well as the properties of all relevant
components.
The key element of this tool is a collection of script-
based data structures, which describe the components
HOTDOCK, SM, WM, and SVC-CLT platform in a
unified manner in terms of mechanical, electrical,
thermal and data link properties as well as system
assembly aspects. These data structures are used as
database for parametrization of the simulator model and
the planner components.
The tool also provides capabilities of visualization
and validation of the configuration (e.g. wrong module /
SI assembly, WM configuration) and steady state
operations of the satellite (e.g. thermal balance), through
the implementation of a special version of the FES (see
after). This offers an early and quick feedback to the
mission team, before starting the full detailed simulation
with the ERGO planner.
Fig.13. Design tool graphical interface in
MATLAB/Simulink
The second tool is the Functional Engineering Simulator
(FES). Based on the Modelica/Dymola technology and
existing libraries. It can simulate with high fidelity the
MOSAR scenarios and operations. It works, together
with the Design Tool, the ERGO Planner and WM
controller, to analyse scenarios and generating
execution plans before going on the real hardware.
For the modular configuration of the satellite in
MOSAR new ways had to be found to implement them
in today’s simulation tools, since normally, they don’t
allow structural variable systems (the number of states
must remain constant). The development of the so-
called tensor bodies within the MOSAR project helped
to overcome this problem. This new innovative
technique will also be useful in other similar projects
where modular elements are part of a system.
Page 8 of 13
 Fig.14. Simulator development in Modelica
4. MOSAR Demonstration
The final demonstration of MOSAR illustrated
successfully the following scenarios, representative of
the preparation and operations of modular spacecraft:
1. Assembly and re-configuration of modular
spacecraft
2. Thermal transfer between two modules, through
their Standard Interconnectors
3. Automatic data and power re-configuration and
recovery
4. Software re-configuration
5. Visual detection of module configuration and
anomalies
4.1 Assembly and Reconfiguration
The purpose of this scenario was to demonstrate the
assembly and reconfiguration of several SMs between
the SVC and the CLT spacecraft buses, including both
the placement of SMs on the CLT itself and on other
SMs.
Regarding the general MOSAR concept, this
scenario is representative of the initial assembly of the
client satellite with modules brought by the servicer
spacecraft, and the replacement of a failed unit on the
CLT.
The scenario was divided in two main set of
operations, first on the Ground Segment for the
preparation and simulation of the plan (Fig.15) and
secondly with the Space Segment and the actions on the
real hardware (Fig.16).
The walking manipulator gets its power and
commands through the HOTDOCK connectors located
on its end-effectors. It follows a reconfiguration plan
that has been computed and simulated before the
operations, based on the initial and final expected
module configuration. At each step, the servicer on-
board computer reconfigures the power and space wire
data network, such that it can reach the robot or the
modules. The manipulator itself is capable to transmit
these signals to the connected module, for instance to
operate the HOTDOCK on the other face of the module.
Fig.15. Ground segment plan computation
Full video of the sequence of operations are
available in [14] and [15].
Following achievements of the demonstrator can be
highlighted:
 Very good performance of the WM, with smooth
operations, and design fully compliant with the
requirements on kinematics, symmetry and
mechanical loads
 High level of repeatability of the operations
 Control operation of the WM in position and
impedance mode, allowing the full reconfiguration
without the need of visual based control
 Demonstration of several type of connections,
highlighting the capability to create different shapes
like 2U and 4U (interconnected by HOTDOCK).
 The good performance of the HOTDOCK SI, with
single, double and triple (diagonal) approach and
simultaneous connection, as well support of the
high loads imposed on the WM base
 Advanced robot walking on top and side of the
modules
4.2 Thermal Management
Two thermal test setup demonstrators have been
integrated in MOSAR (Fig.17)). The purpose of the first
setup was to characterise the functions and
performances of the HOTDOCK SI fluidic interface. It
allowed to determine the possibility to achieve a thermal
flow transfer up to 2500W. The thermal circuitry has
also been designed to ensure non-leakage operations,
especially during the phases of connection and
disconnection of HOTDOCK. During the final project
integration, the thermal circuitry has been integrated in
two representative SM. The thermal transfer between
the two modules and the non-leakage strategies have
been again demonstrated.
Page 9 of 13
 Fig.16. Space Segment Operations Sequence

4.3 Data and Power Reconfiguration and Recovery main bus of the Client satellite. The battery module is
then able to automatically detect the absence of power
Data and power recovery and routing
from the nominal bus. It can then initiate successive
reconfiguration have been validated on the assembled
adaptation of the power network, such that the battery is
Client satellite setup, with a 2x2 SM configuration, as
able to power again all the other modules. This is
obtained at the end of the scenario 1 assembly (Fig.18).
achieved by a reconfiguration of the cPDU board
For the data network, the purpose was to validate the output. As function of the selected spacecraft
ability of the SpaceWire network to automatically detect architecture, the detection and reconfiguration
and adapt to faulty interfaces. The fault-mitigation operations can be either performed by the cPDU or the
aspect was tested by disabling the HOTDOCK attached R-ICU.
SpaceWire connection between two SM, leading to the
impossibility to communicate with other modules (cut
in the path). The developed algorithms have then the
possibility to detect the absence of communication and
initiate a network discovery to find another path to the
lost modules. Once done, the network is automatically
reconfigured and the nominal operations of the satellite
can be recovered.
The possibility of reconfiguration of the power network
has been validated by a scenario of power failure of the

Page 10 of 13
 Communication Model) that was added to Cheddar
during the MOSAR project appeared to be less
pessimistic and confirmed the schedulability of the
system.

Fig. 17. Top: Thermal standalone test setup, Bottom:

SM integrated thermal test setup

Fig.19. TASTE Concurrency View simulation with

timing analysis
4.5 Visual Detection
Although the MOSAR system is fully autonomous,
it is very important for future applications in the outer
space environment to support the operations to be full
autonomous for unplanned events through visual
inspection. Based on the previous project Infuse,
external visual detection algorithms have been further
developed in MOSAR and demonstrated. The setup was
Fig.18. Spacecraft Module setup for data and power based on stereo cameras RGB-D to capture stereo
reconfiguration and recovery images for module recognition and detection. It allows
for example to automatically validate the spacecraft
4.4 Software Reconfiguration configuration as well detect defects or missing elements
that would have an impact on the further autonomous
The objective of the software reconfiguration was to operations.
demonstrate the ability of the TASTE/AADL approach
to ease software development for reconfigurable
spacecraft, and anticipate possible scheduling issues at
design time for software running in different operational
modes corresponding to spacecraft hardware
configurations.
With this demonstration, several timing analysis
techniques were applied to an AADL model
representing the MOSAR Client satellite software
architecture and its deployment onto processor boards
communicating via a SpaceWire network.
Timing analysis with the Marzhin simulator showed
the behavior of the software during a change of the Fig.20. Visual system setup and detection of module
satellite configuration but did not detect any scheduling configuration
issue even when all the payloads were active. On the
contrary, Worst Case timing analysis with Cheddar 5. MOSAR Impact
could only provide results in a steady configuration but Through all the MOSAR activity many space
found possible task deadline misses. Finally, a finer relevant technologies have been further developed,
model of the spacewire network (SCM: Spacewire

Page 11 of 13
matured and demonstrated in an integrated system. On a
short term (next 2-3years), this will have a direct
positive impact on the on-going and new space robotic
projects, through their re-use or adaption, both in the
institutional (e.g. ESA, next OGs) and industrial context.
We also expect the upcoming IOD call of the Space
Robotics Technologies SRC (likely in 2021) to be the
opportunity to increase the TRL level and to of a flight
demonstration for MOSAR technologies, as mean to
pave the way toward concrete exploitation.
Several of the MOSAR technologies target a
standardization of their design. This is mainly including
the SRC building blocks, HOTDOCK and the spacecraft
modules. The expected benefits of the standardization of
these technologies are the cost effectiveness of their
implementation, the reduction of development,
production and integration time, the setup of common
robotics technological framework… The standardization
is also one of the main requirement for the performance
and cost effectiveness of future modular systems. We
can highlight, already that several technologies, like
ESROCOS, ERGO, HOTDOCK, were used in different
SRC projects of the second call, creating the foundation
of such standardization, at least on the European level.
It is expected that this will continue through the next
calls, although this will also require to join the industrial
sphere in order to ensure the sustainability of these
standardizations.
The implementation of MOSAR technologies like
the ERGO, the simulator, HOTDOCK SI, the walking
manipulator will definitively favour the development of
autonomous space systems that can have an important
influence for future space missions and creating new
opportunities for space industry. Autonomous solution
will also favour the development of servicing missions
that will improve space mission sustainability and cost
effectiveness.
On a longer term, MOSAR is proposing a
fundamental shift of paradigm in the design and
operation of spacecraft. This will not be applicable to all
space missions and this is of course not something that
will be possible do on a short term, due to the current
approach of the space missions and the different
technological and costs constraints. There is however
clearly an increase of interest for the On-Orbit servicing
topic, which is the first step towards the final solution
promoted by MOSAR. The exploitation review and
analysis has highlighted the most relevant missions as
well as the possible development and exploitation
roadmap to facilitate this transition. This provides a
basis on what MOSAR partners or other institutions and
companies can develop their next activities.
The successful performance of the final MOSAR
demonstrator, with the full satellite assembly and re-
configuration, is a wonderful vitrine to promote the
topic of on-orbit servicing and further spacecraft
modularity to the industry. It shows, at some level, the
feasibility of this proposition as well as the good
performances of the components. This should enhance
the collaboration with MOSAR partners and possibly
the innovation around these topics, with the final goal to
enable new business cases not yet envisaged today.
Moreover, the general operational concept of MOSAR
is not limited to modular spacecraft. The autonomous
operations and the robotic technologies are also very
valuable for other space mission scenarios, like structure
assemblies.
Most of the MOSAR technologies have a possible
synergy with terrestrial applications. We can highlight
the robotic manipulator, which has been fully operated
in 1g conditions. It is offering a fully integrated solution
(with embedded controller) and very high performance
in terms of lifting to weight ratio, opening a lot of
possibilities.
6. Conclusion and Perspectives
The MOSAR project succeeded in demonstrating, in
laboratory conditions, the concept of assembly and
reconfigurable spacecraft, as well highlighting typical
operations around modular satellite architecture as
power, data, thermal and software management. On top
of that, vision based detection is a new promising
feature of MOSAR to support future autonomous
system.
Beside the achievement of the integrated system, we
can also highlight that MOSAR enabled the
development of several highly relevant technologies for
future European Space activities and related industries.
This is including the further development of all the SRC
building blocks (ESROCOS, ERGO, INFUSE, I3DS),
HOTDOCK, the Walking Manipulator, the Design and
Simulation tools (FES), the Spacecraft Modules and the
Thermal Management system.
Several of these technologies are already applied in
on-going projects. PERIOD and EROSS + are direct
follow-up projects targeting the definition of the In-orbit
demonstration of assembly and servicing operations.
Also other European and ESA initiatives will directly
benefit from the output of MOSAR, as MIRROR
dedicated to the assembly of large telescope structure
[16].
Acknowledgements
MOSAR was funded by the European Commission
Horizon 2020 programme under grant number 821966.
Page 12 of 13
 References
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https://www.youtube.com/watch?v=8F4kJZAv09w
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