Propellant transfer system and method for resupply of fluid propellant to on-orbit spacecraft

1. A method of refueling a client satellite, comprising:

a) maneuvering a servicer spacecraft into close proximity to a client satellite in a position and orientation suitable to releasibly couple the client satellite to the servicer spacecraft, releasibly coupling the client satellite to the servicer spacecraft;

b) deploying, and commanding, a robotic arm mounted on the servicer spacecraft to releasibly grasp a multifunction tool, commanding the robotic arm to manipulate the multifunction tool to access a fill/drain valve on the client satellite in flow communication with a storage tank on the client satellite;

c) commanding the robotic arm to sequester the multifunction tool and releasibly grasp a refueling tool, commanding the robotic arm to manipulate the refueling tool to releasibly grasp a propellant outlet hose connected to a propellant transfer system and connect the propellant outlet hose to the fill/drain valve;

e) opening the fill/drain valve and measuring a pressure in the client satellite storage tank and, based on the measured pressure, configuring a flow control system mounted on the servicer spacecraft to transfer propellant under regulated pressure and flow rate conditions suitable for the measured pressure;

f) commanding the configured flow control system of the propellant transfer system to transfer propellant from a propellant storage tank on the servicer spacecraft through a piping system to the propellant hose to the storage tank on the client satellite;

g) once a desired quantity of propellant has been transferred to the client satellite, commanding the robotic arm to manipulate the refueling tool to close the fill/drain valve;

h) disconnecting the propellant hose from the fill/drain valve and sequester the propellant hose; and

i) sequestering the robotic arm and decoupling the servicer spacecraft from the client satellite.

2. The method according to claim 1 wherein in step c) prior to commanding the robotic arm to mate the propellant hose to the fill/drain valve, commanding the robotic arm to manipulate the refueling tool to releasibly grasp a backup fill/drain valve and mate the backup fill/drain valve with the fill/drain valve on the servicer spacecraft, and thereafter commanding the robotic arm to manipulate the refueling tool to releasibly grasp the propellant hose and mate it to the backup fill/drain valve and to open both the fill/drain valve and the backup fill/drain valve.

3. The method according to claim 2 including monitoring pressure over periods of time in the piping system after the fill/drain valve and the backup fill/drain valve are opened for detection of leaks.

4. The method according to claim 3 wherein the periods of time include periods of time both before and after transferring propellant to the client satellite.

5. The method according to any one of claim 1 wherein in step e) of measuring the pressure of the client satellite storage tank, when the pressure measured is lower than that of the servicer spacecraft's propellant storage tank, the step of configuring a flow control system mounted on the servicer spacecraft to dispense propellant under regulated pressure and flow rate conditions suitable for the measured pressure includes providing a first flow path through the propellant transfer system and providing regulated flow of

i) pressurized gas between at least one pressurized gas tank and at least one propellant storage tank contained in the propellant transfer system, and

ii) propellant between said at least one propellant storage tank and said propellant outlet hose.

6. The method according to claim 5 wherein in step e) of measuring the pressure of the client satellite storage tank, when the pressure is higher than that of the servicer spacecraft's propellant storage tank up to a set point for pressure regulators in a high pressure section piping system associated with said at least one pressurized gas tank, the step of configuring a flow control system mounted on the servicer spacecraft to dispense propellant under regulated pressure and flow rate conditions suitable for the measured pressure includes providing a second flow path through the propellant transfer system and providing regulated flow of propellant from at least one storage tank to a fluid volume of at least one propellant transfer tank facilitated by venting a gas volume of said at least one transfer tank to space and opening a flow path between at least one propellant storage tank and said fluid volume, and after a desired quantity of propellant has transferred to said fluid volume then cease venting said gas volume to space, and thereafter pressurizing the gas volume and opening a flow path from said fluid volume to said propellant outlet hose thereby forcing the propellant to flow from said fluid volume to said propellant outlet and into the client satellite storage tank.

7. The method according to claim 2 wherein step g) further includes the steps of commanding the robotic arm to manipulate the refueling tool to disconnect the backup fill/drain valve from the client satellite fill/drain valve and sequester the backup fill/drain valve, and commanding the robotic arm to manipulate the refueling tool to releasibly grasp a replacement secondary seal fitting and couple the replacement secondary seal fitting to the client satellite fill/drain valve.

8. The method according to claim 1 wherein step g) further includes the steps of commanding the robotic arm to manipulate the refueling tool to releasibly grasp a replacement secondary seal fitting and couple the replacement secondary seal fitting to the backup fill/drain valve thereby leaving behind the backup fill/drain valve still connected to the client satellite fill/drain valve.

9. The method according to claim 1 wherein said client satellite uses a monopropellant, and wherein monopropellant is transferred from said servicer spacecraft to said client satellite.

10. The method according to claim 1 wherein said client satellite uses a bipropellant including a fuel and an oxidizer, and wherein steps b), c), d), e), f), g) and h) are first carried out for transferring fuel to an associated fuel propellant tank on the client satellite, and then steps b), c), d), e), f), g) and h) are repeated for transferring oxidizer to an associated oxidizer propellant tank on the client satellite.

11. The method according to claim 1 wherein said commands are issued through a communication system configured to provide communication between said command and control system and a remote operator for remote teleoperation control, supervised autonomous control, or fully autonomous control of propellant transfer operations between the servicer spacecraft and the client satellite.