Centaur-M Assembly
TL;DR
- Purpose: Manipulator robot for assembly and maintenance
- Mass: ~380 kg
- Battery: NaS 5 kWh + cable (optional)
- Power: 5 kW
- Assembly time: 38 hours per station
Overview
Centaur-M is a universal Gen-2 manipulator robot for precision operations: equipment assembly, welding, maintenance. Four-wheel platform with two 6-axis manipulators and a tool set.
Key feature: The lightest Gen-2 robot (380 kg), maximum aluminum fraction (62%) to reduce mass.
Centaur-M Material Balance
| Component | Material | Mass | Source |
|---|---|---|---|
| Frame + chassis | Steel Fe-6%Mn | 80 kg | Frame Manufacturing |
| Body, radiators, manipulators, sensor housings | Aluminum | 235 kg | Aluminum |
| NaS Battery | Na + S + β-Al₂O₃ | 40 kg | Battery Production |
| Actuators (16 pcs: 4 wheels + 2×4 direct-drive + 2×2 tendon) | Fe + Al + NdFeB | 25 kg | Actuators |
| Electronics (chips) | — | 0.3 kg | Import from Earth |
| TOTAL | — | ~380 kg | >99% local |
Material distribution: - Iron (Fe): 80 kg = 22% - Aluminum (Al): 235 kg = 63% - Sodium + Sulfur: 40 kg = 11% - Actuators: 25 kg = 7% - Import (chips): 0.3 kg = <0.1%
Electronics 5 kg = chips 0.3 kg (import) + camera/lidar housings, cables ~4.7 kg (Al, local)
Design
Dimensions
| Parameter | Value |
|---|---|
| Length | 2.5 m |
| Width | 1.5 m |
| Height | 1.8 m (to manipulator top) |
| Ground clearance | 0.3 m |
| Manipulator load capacity | 2×50 kg = 100 kg total |
Manipulators
2 manipulators with 6 axes each:
| Parameter | Value |
|---|---|
| Manipulator length | 1.2 m |
| Load capacity | 50 kg at 1 m distance |
| Positioning accuracy | ±2 mm |
| Movement speed | 1 m/s |
| Material | Aluminum (lightweight) |
±0.5 mm achievable in controlled conditions (under dome, on cable). On open ground — ±2 mm due to thermal deformation.
Tools (interchangeable attachments): - TIG welding torch (vacuum, no gas required) - Grinding head (abrasive Al₂O₃) - Universal gripper (electromechanical) - Torque-adjustable screwdriver - 3D laser scanner
Assembly Process
Assembly Line (10 stations, 38 hours per station)
| Station | Stage | Time | Robots |
|---|---|---|---|
| 1 | Frame installation on jig | 1 hour | 1 Centaur-M |
| 2 | Chassis mounting (4 wheels) | 3 hours | 2 Centaurs-M |
| 3 | Al body and radiator installation | 4 hours | 2 Centaurs-M |
| 4 | NaS battery installation (5 kWh) | 2 hours | 1 Centaur-M |
| 5 | 2 manipulator mounting (6+6 axes) | 12 hours | 3 Centaurs-M |
| 6 | Power cable routing | 3 hours | 1 Centaur-M |
| 7 | Electronics installation (processor, sensors) | 4 hours | 2 Centaurs-M |
| 8 | NaK cooling loop filling | 1 hour | 1 Centaur-M |
| 9 | Manipulator calibration and testing | 4 hours | Automated |
| 10 | Initial battery charging | 4 hours | Charging station |
| TOTAL | 38 hours |
Stage 1: Frame Installation
Centaur-M Frame: - Mass: ~320 kg (70 kg Fe + 200 kg Al + 50 kg other) - Design: Lightweight aluminum frame with steel load-bearing nodes - Production: WAAM 3D printing
Process: 1. Crane lifts frame from conveyor 2. Frame installed on assembly jig 3. Fixed on 4 supports 4. Geometry verification (laser scanner)
Stage 2: Chassis Mounting
4 wheels: - Diameter: Ø1.2 m (unified with Mole-M/Crab-M) - Width: 0.6 m - Material: Al rim + Fe-6%Mn band (local) - Drive: Electric motors 2 kW × 4 = 8 kW + cycloidal gearbox 1:20
Suspension: - Independent on each wheel - Hydraulic shock absorbers (NaK) - Suspension travel: ±150 mm
Process: 1. Install 4 hubs on frame (M16 bolts) 2. Mount 2 kW electric motors with cycloidal gearboxes 1:20 3. Install wheels 4. Alignment adjustment
Stage 3: Body and Radiator Installation
Aluminum body: - Mass: 100 kg (part of 230 kg Al) - Design: Lightweight panels from 2 mm Al sheets - Function: Electronics protection, radiators
Radiators: - Area: ~5 m² (oriented toward shadow) - Material: Aluminum - Loop: NaK cooling for battery and processor
Process: 1. Install side panels (bolts + rivets) 2. Mount radiators on roof 3. Seal joints (TIG welding)
Stage 4: NaS Battery Installation
NaS Battery 5 kWh: - Mass: 40 kg - Voltage: 200 V (100 cells × 2 V) - Placement: Center of gravity (under platform)
Optional cable: - For factory work, Centaur-M can operate from cable (10 kV) - Cable reel on body (50 m) - Automatic rewind on return
Process: 1. Lift battery with crane 2. Install in battery compartment 3. Connect power cables (M8 bolts) 4. Connect battery management system (BMS)
Details: Battery Production
Stage 5: Manipulator Mounting
2 manipulators with 6 axes:
- Joints 1-4: direct-drive (NdFeB magnets, import) — zero backlash, zero gearbox maintenance
- Joints 5-6 (wrist): tendon drives — motor on body, wire through pulleys (100% local materials)
Installation process: 1. Mount manipulator base on frame (M20 bolts) 2. Install 6 manipulator links (each link — 200 mm) 3. Install 4 direct-drive motors (joints 1-4) + 2 tendon drives (joints 5-6) 4. Route power and signal cables through manipulator 5. Install interchangeable attachment (TIG torch by default)
Time: 12 hours for 2 manipulators (most labor-intensive stage)
Details: Actuators
Stage 6: Power Cable Routing
Cables: - Main power cable: 25 mm² Al (200 V, 50 A) - Manipulator control cables: 2×6 wires (axis signals) - Tool power cable: 16 mm² Al (for welding, milling)
Process: 1. Route cables through cable channels 2. Connect to distribution panel 3. Insulation test (megohmmeter)
Stage 7: Electronics Installation
Centaur-M Electronics: - Processor: ARM Cortex-A72 (4 cores, 1.5 GHz) - Sensors: 8 cameras, 2 lidars, GPS, IMU - Communication: Wi-Fi, 2.4 GHz radio channel - Mass: 5 kg
Process: 1. Install computer in protective enclosure 2. Connect cameras and lidars 3. Calibrate sensors 4. Install communication antennas
Stage 8: NaK Cooling Loop Filling
NaK Loop: - Volume: ~20 liters - Temperature: +50-100°C (operating) - Radiators: 5 m² Al panels
Process: 1. Evacuate loop (remove air) 2. Fill NaK through fill valve 3. Leak test (vacuum test) 4. Start NaK pump
Stage 9: Manipulator Calibration and Testing
Test Program:
| Test | Description | Standard |
|---|---|---|
| Manipulator calibration | Set zero positions for all 12 axes | Accuracy ±2 mm |
| Movement | Check all 4 wheels | Speed 5 km/h |
| Load pickup | Lift 50 kg at 1 m distance | Position accuracy ±3 mm |
| TIG welding | Weld test on Al plates | Defect-free weld |
| Battery | Full charge/discharge cycle | Capacity >4.5 kWh |
| Autonomy | Autopilot, obstacle avoidance | 100% success |
Duration: 4 hours (automated calibration with laser scanner)
Stage 10: Initial Charging
Charging Station: - Voltage: 200 V - Current: 25 A - Full charge time: 1 hour (5 kWh / 5 kW)
Process: 1. Connect to charging station 2. Activate battery (first cycle at 350°C) 3. Full charge 4. Capacity verification (must be >4.5 kWh)
Power Consumption
| Mode | Power | Operating Time |
|---|---|---|
| Movement | 2 kW | 2.5 hours (12 km) |
| Manipulator work (positioning) | 1 kW | 5 hours |
| TIG welding | 5 kW | cable only |
| Abrasive grinding | 3 kW | cable only |
| Idle | 0.2 kW | 25 hours |
Note: Energy-intensive operations (TIG welding, grinding) are performed on cable power in factory conditions. The 5 kWh battery is designed for transit between facilities and manipulator positioning.
Range (on battery): - Movement: 12 km - Manipulator work: 5 hours
Maintenance
| Operation | Frequency | Performed by |
|---|---|---|
| MoS₂ joint bearing recoating | 3-6 months | Magnetron station + another Centaur-M |
| Manipulator calibration | 1 month | Automated |
| NaS battery replacement | 5-7 years | Assembly line |
| Tool replacement (TIG torch, cutters) | As needed | Centaur-M self-service |
Service life: - Frame: 10-15 years - Manipulators: 5-10 years - Battery: 5-7 years (4500 cycles) - Electronics: 5-10 years - Robot overall: 5-10 years
Applications
Main Centaur-M tasks:
| Task | Description | % of time |
|---|---|---|
| Robot assembly | Component mounting on jig | 40% |
| Structure welding | TIG welding Al/Fe parts | 20% |
| Grinding | Abrasive processing of mounting surfaces | 15% |
| Equipment maintenance | Part replacement, adjustment | 15% |
| Testing | Product quality control | 10% |
Productivity: - 1 Centaur-M can assemble 0.2 robots/day (5 Centaurs → 1 robot) - 1 Centaur-M can service 20 equipment units/day
Centaur-M Tools
TIG Welding Torch
| Parameter | Value |
|---|---|
| Current | 10-200 A |
| Environment | Vacuum (no shielding gas required) |
| Electrode | Tungsten (W) |
| Application | Al/Fe welding |
Grinding Head
| Parameter | Value |
|---|---|
| Power | 3 kW |
| Rotation speed | 3,000-6,000 rpm |
| Abrasive | Al₂O₃ (corundum, local) |
| Application | Mounting surface processing |
Universal Gripper
| Parameter | Value |
|---|---|
| Load capacity | 50 kg |
| Type | Electromechanical (servo) |
| Grip accuracy | ±1 mm |
See also
- Robot Production — production overview
- Frame Manufacturing — lightweight Al frame for Centaur-M
- Battery Production — NaS 5 kWh
- Actuators — 12 electric actuators for manipulators
- Crab-M Assembly — logistics robot
- Mole-M Assembly — excavator robot