As reported by the European Space Agency (ESA) in the article “Spacecraft Dockings Improve Car Assembly,” technology originally designed for docking spacecraft with the International Space Station (ISS) is now being used to enhance precision in car assembly lines. At Volkswagen’s Autoeuropa plant in Palmela, Portugal, a system developed by MDUSpace at ESA’s Business Incubation Centre is helping to install dashboards with the same meticulous control that guides a spacecraft during docking.

This breakthrough system combines live camera feeds with advanced object-recognition software, which calculates the precise distance between a car and the manipulator arm placing the dashboard. Inspired by ESA’s Automated Transfer Vehicle (ATV) docking technology, the system keeps the manipulator and car perfectly synchronized in speed and position, eliminating potential damage from misalignment. Traditional synchronization methods often involve complex wiring and control systems or mounting the manipulator onto the car, which risks structural stress. This new approach removes these complications, improving assembly line efficiency and safeguarding the vehicle.

Miguel Brito, business developer of MDUSpace, explains that the system functions similarly to how the ATV approaches the ISS. The spacecraft’s camera identifies light pulses from special targets on the ISS, allowing the software to determine exact positioning. In automotive assembly, reference points on the car serve as targets, enabling the manipulator to maintain a consistent position as the car moves along the line.

This innovation represents a major step forward for automotive manufacturing, blending space-grade technology with production line efficiency to deliver precision and cost-effectiveness.

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Article with all rights reserved, courtesy of ESA.