Design and experimental validation of a docking interface for orbital refueling

This work addresses the need for standardized in-space refueling technologies by presenting the design and experimental validation of a Docking Interface for Orbital Refueling. A comprehensive review of existing refueling demonstrations, missions, and associated technologies is first provided. Taking into account the key aspects of these refueling technologies, a novel design is proposed with a compact interface between the servicer and client. The mechanism features a magnetic cone docking connection, grappling arms inspired by Dawn Aerospace’s and Orbit Fab’s capture method, and an electric pump-based fuel transfer approach. The complete end-to-end refueling operation—including docking, capture, and fluid transfer—is experimentally validated on a planar air-bearing testbed. The experimental validation campaign conducted with Carleton University’s Spacecraft Proximity Operations Testbed demonstrates consistent and successful leak-free fluid transfers under varying docking angles and approach speeds. For in-space operations, alterations to the current laboratory prototype are discussed. • Review of existing refueling demonstrations and technologies. • Design of DIOR; an innovative docking and refueling mechanism. • Discussion on expanding the design to six-degree-of-freedom environments. • Three-degree-of-freedom testing on an air-bearing table, at varying approach speeds and angles. • Integration with computer vision and guidance, navigation, and control for final end-to-end testing.