Northrop’s robot space mechanic is a new way to keep satellites at work longer

In the high skies above Earth, a novel approach to extending the lifespan of satellites is being developed. This innovative method involves the deployment of specialized robots, a departure from previous methods of satellite maintenance. This week, a spacecraft operated by Northrop Grumman, known as a Mission Extension Vehicle (MEV), detached from a communications satellite belonging to Optus.

The MEV had been attached to the Optus satellite for over a year, maintaining its position in space to ensure continued operation. The mission extension spacecraft is now preparing to make way for its replacement. In July, four new Northrop Grumman spacecraft were launched into orbit on a SpaceX Falcon 9 rocket. One of these, the Mission Robotic Vehicle (MRV), is a high-tech satellite equipped with advanced robotic arms, created by the U.S. military research organization, DARPA.

The other three spacecraft, known as Mission Extension Pods (MEPs), are smaller and simpler satellites serving as modular propulsion systems. These four spacecraft are currently en route to their designated targets, located approximately 27,000 miles above Earth. By 2027, the MRV will utilize its robotic arms to attach one of the MEP pods to the Optus satellite, extending its operational life for years.

Communication or Earth observation satellites have a limited lifespan, typically failing when their fuel reserves are depleted rather than due to hardware malfunction. The Optus satellite, launched in 2009, was designed to operate for 15 years, but with successful life extension, it could continue for another six years. Lower costs for satellite launches and components are making satellite repair missions a tangible possibility.

Northrop Grumman's Cassie Wong, the Director of Logistics and Servicing, envisions a shift towards a more sustainable space infrastructure where services such as satellite repairs, life extension, and upgrades become the norm. Two MEVs are currently in orbit, having provided 10 years of life extension to three customers, including two Intelsat spacecraft and the Optus satellite.

MEV-1 will remain in a parking orbit awaiting its next assignment, while MEV-2 is currently attached to its Intelsat customer until 2030. The MRV signifies an advancement in this business model, as satellite operators own the MEPs, which remain permanently attached to their spacecraft. This arrangement allows the MRV to service multiple vehicles, reducing costs and increasing efficiency.

The MRV's complex technology requires the vehicles to autonomously approach and dock with satellites moving at high velocities. The MEVs use a docking probe to connect and secure to satellite thruster nozzles, while the MRVs will need to carefully attach the MEPs using their robotic arms. Currently, the high cost and weight of such adaptations deter many satellite operators from investing in them.

Yet, the trend in satellite technology involves launching numerous inexpensive, replaceable spacecraft in low orbits, such as those operated by Starlink and Amazon LEO. However, satellites are becoming larger and more expensive, with many large satellites in orbit that could benefit from life extension. Wong hopes that the MRV will perform additional tasks, such as adding new components to satellites and adjusting their orbits, which could potentially include defense-related missions.

Northrop Grumman emphasizes that their vehicles are intended for servicing missions and not to serve as weapons. The MRV could also be utilized in low Earth orbit (LEO) to extend the lifespan of valuable assets there. Meanwhile, a startup called Katalyst Space is attempting a similar mission to extend the life of a NASA space telescope that malfunctioned last month. The company has a solution in place and aims to complete the mission.