TransforMARS: Fault-Tolerant Self-Reconfiguration for Arbitrarily Shaped Modular Aerial Robot Systems

Modular Aerial Robot Systems (MARS) consist of multiple drone modules that are physically bound together to form a single structure for flight. Exploiting structural redundancy, MARS can be reconfigured into different formations to mitigate unit or rotor failures and maintain stable flight. Prior work on MARS self-reconfiguration has solely focused on maximizing controllability margins to tolerate a single rotor or unit fault for rectangular-shaped MARS. We propose TransforMARS, a general fault-tolerant reconfiguration framework that transforms arbitrarily shaped MARS under multiple rotor and unit faults while ensuring continuous in-air stability. Specifically, we develop algorithms to first identify and construct minimum controllable assemblies containing faulty units. We then plan feasible disassembly-assembly sequences to transport MARS units or subassemblies to form target configuration. Our approach enables more flexible and practical feasible reconfiguration. We validate TransforMARS in challenging arbitrarily shaped MARS configurations, demonstrating substantial improvements over prior works in both the capacity of handling diverse configurations and the number of faults tolerated. The videos and source code of this work are available at the anonymous repository: https://anonymous.4open.science/r/TransforMARS-1030/