Handheld Dual-Point Docking Mechanism for Spacecraft On-Orbit Service of Large-Scale Payloads

The rapid development of spacecraft on-orbit services has increased the requirements for docking technology, especially for large-scale payloads that exceed the launch envelope. Docking technology based on astronaut extravehicular activities is one of the most promising directions for on-orbit services. In view of this, this paper designs and characterizes a handheld double-point docking mechanism for assembling large-scale payloads that is suitable for extravehicular activity (EVA) in dual-astronaut collaborative operations. It achieves the functional decoupling of docking, locking, unlocking, and separation throughout the whole process. The mechanism also has excellent design for human factors engineering, allowing astronauts to change hands, operate with one hand, and apply limited force. The mechanism adopts a dual-point probe–drogue configuration, while the misalignment tolerance design guarantees the docking accuracy and the operating range, and forms a rigid structural connection through a force amplification mechanism. Theoretical analysis and numerical simulations are implemented to estimate the dynamics, statics, and kinematics of the docking process. Corresponding experiments of the prototype are also conducted, including high–low temperature dynamics, docking tests, and kinematic tolerance experiments. The experiments validate the finite element analysis and verify the actual performance of the mechanism. The designed handheld dual-point docking mechanism was successfully applied for the first time by the Shenzhou 15 crew on China’s Space Station in March 2023. This paves a new road for spacecraft on-orbit service of large-scale payloads by EVAs, providing guidance as well as a technical foundation for the on-orbit construction of large spacecraft in the future.