Document Type

Report

Publication Date

Spring 2026

Abstract

This project presents the design, development, and testing of a low-cost optical force/torque sensor for Skyforge, an autonomous robotic system intended for in-space construction. The sensor utilizes eight optical transmissive sensors and a compliant PEEK spring mechanism to measure forces and torques across six degrees of freedom. By detecting spring deflections through changes in light intensity, the system provides real-time force and torque feedback while remaining significantly less expensive than commercially available alternatives. The prototype was designed to measure forces up to ±5 N and torques up to ±50 N·mm with a target minimum detectable force of 0.5 N. Calibration was performed using known masses applied along each axis, and testing evaluated the sensor's accuracy, precision, range, and repeatability. Results demonstrated force detection as low as 0.25 N and torque detection as low as 5 N·mm, with repeatability variations below 1.89%. While improvements in sensor alignment, calibration methods, and test apparatus stiffness are needed to achieve the full design range, the prototype successfully demonstrates the feasibility of a low-cost optical force/torque sensor for robotic space applications and provides a foundation for future flight-ready designs.

Notes

Course: ENP 495, Engineering Senior Capstone III (Dr. Peter Staritz)

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