Satellite skeleton on-orbit manufacturing process and on-orbit manufacturing robot

Abstract

The application discloses a satellite framework on-orbit manufacturing process and an on-orbit manufacturing robot, and belongs to the technical field of on-orbit manufacturing. The satellite framework on-orbit manufacturing process comprises the following steps: a plurality of meridian shafts are made outside a positioning disc; carbon fiber bundles are woven or wound outside each meridian shaft, the carbon fiber bundles cover the meridian shafts, and the meridian carbon fiber bundles covering the meridian shafts are cured to form meridian parts of the satellite framework; the plurality of meridian parts are interwoven in the weft direction by using the spiral carbon fiber bundles, and the weft carbon fiber bundles are cured to form weft parts of the satellite framework, and finally, the satellite framework has a spiderweb structure. The satellite framework on-orbit manufacturing process can reduce the volume of a launched satellite framework part, weave a satellite framework part of a predetermined size on an orbit, and avoid the problems of vibration and size limitation caused by a large satellite framework part during satellite launching.

Description

Technical Field

[0001] This invention relates to the field of on-orbit manufacturing technology, specifically to an on-orbit manufacturing process for a satellite skeleton and an on-orbit manufacturing robot. Background Technology

[0002] The satellite skeleton is a key structural component of large satellites, primarily serving a load-bearing function. Traditionally, the entire satellite skeleton is manufactured on the ground, folded and compressed, and then launched into orbit by a rocket, ultimately deploying for service in orbit. However, this method is insufficient for deploying large-sized satellites and introduces design requirements unrelated to the long-term space environment.

[0003] To overcome these limitations, the on-orbit assembly technology approach is currently widely used to deploy large-sized satellites with various structures. However, the structure of on-orbit assembly technology is complex, and due to the limitations of the launch platform, the size of the satellite skeleton components cannot be too large. Furthermore, the vibration generated by the satellite skeleton during satellite launch affects the launch safety of the satellite. Summary of the Invention

[0004] The purpose of this invention is to overcome the problems in the prior art and provide an on-orbit manufacturing process for satellite skeletons that can reduce the volume of launched satellite skeleton components, avoid the size limitations of satellite skeleton components and the resulting vibration problems during satellite launch.

[0005] This invention provides an on-orbit manufacturing process for a satellite skeleton, which is fabricated on a positioning disk launched into space orbit, and includes the following steps:

[0006] Multiple radial mandrels are fabricated outside the positioning disk, and the multiple radial mandrels are arranged radially with the positioning disk as the center;

[0007] Carbon fiber bundles are woven or wound around each meridional mandrel, covering the meridional mandrels, and the meridional carbon fiber bundles covering the meridional mandrels are cured to form the meridional part of the satellite skeleton;

[0008] Starting from the positioning disk, carbon fiber bundles are used to interweave multiple warp sections in a spiral shape, and the latitudinal carbon fiber bundles are then solidified to form the latitudinal section of the satellite skeleton. The final satellite skeleton has a spider web-like structure.

[0009] Preferably, the manufacturing process of the plurality of meridional mandrels is as follows: multiple tubular meridional mandrels are printed on the outer edge of the positioning disk using additive manufacturing; or multiple compressed cylindrical airbags are set on the outer edge of the positioning disk, and multiple compressed cylindrical airbags located in space are inflated to allow the multiple cylindrical airbags to inflate and expand, forming multiple meridional mandrels.

[0010] Preferably, when using carbon fiber bundles to weave multiple warp sections in the weft direction, multiple warp sections need to be woven repeatedly in both forward and reverse directions to make the weft carbon fiber bundles present a concentric multi-helix structure.

[0011] Preferably, after the columnar airbag is wrapped or woven with carbon fiber bundles, a hot airflow is introduced into the columnar airbag to heat and solidify the carbon fiber bundles.

[0012] Preferably, the positioning disk has a polygonal structure, and each vertex of the positioning disk is provided with a storage compartment, and each storage compartment is provided with a compressed cylindrical airbag.

[0013] Preferably, the positioning disk has multiple spokes, one end of which is connected together, and the other end of each spoke is connected to a vertex of the positioning disk.

[0014] Preferably, the columnar airbags have a certain curvature, and the center of curvature of each columnar airbag is oriented toward the central axis of the positioning disk.

[0015] Preferably, the columnar airbag is made of a thin film material.

[0016] The present invention also provides an on-orbit manufacturing robot for manufacturing the warp and weft sections of a satellite skeleton. The robot includes a winding section and a curing section, with the curing section located behind the winding section. The winding section is used to wind carbon fiber bundles around the warp mandrel or to weft-interweave multiple warp sections using carbon fiber bundles. The curing section is used to heat and cure the warp or weft carbon fiber bundles.

[0017] Preferably, the winding part includes a traveling mechanism, a swinging mechanism, and a reciprocating mechanism. The traveling mechanism is used to travel on multiple warp mandrels. The traveling mechanism is provided with a discharge mechanism. The discharge mechanism contains carbon fiber bundle raw materials. The carbon fiber bundle discharged by the discharge mechanism passes through the swinging mechanism and enters the reciprocating mechanism. The reciprocating mechanism is provided with a ring arm. The reciprocating mechanism winds the carbon fiber bundle onto the warp mandrel through the ring arm.

[0018] Compared with existing technologies, the beneficial effects of this invention are as follows: The on-orbit manufacturing process for a satellite skeleton according to this invention can reduce the volume of the launched satellite skeleton components and weave satellite skeleton components of a predetermined size in orbit, avoiding the size limitations of satellite skeleton components and the resulting vibration problems during satellite launch. By using multiple warp sections of carbon fiber bundles for repeated forward and reverse interlacing, the interlaced weft carbon fiber bundles can form a concentric multi-helix structure. This multi-helix structure has higher structural stability and reliability, thereby improving the overall robustness and shock resistance of the satellite skeleton. After the carbon fiber bundles are wound around the columnar airbags, hot gas is injected into the hollow columnar airbags to heat the matrix material and accelerate curing. The high vacuum environment results in slower heat dissipation, leading to lower energy consumption during carbon fiber bundle curing, thus reducing the energy consumption during the overall satellite skeleton weaving process. By setting the positioning disk as a polygonal structure, after the multiple columnar airbags are fully deployed, the entire warp section forms a spoke-like structure, facilitating the subsequent weft weaving of the multiple columnar airbags using carbon fiber bundles. By incorporating multiple spokes, with one end of each spoke connected to a common point and the other end of each spoke connected to a vertex of the polygonal positioning disk, the structural strength of the entire positioning disk is enhanced, thereby further improving the overall robustness and seismic resistance of the satellite frame. The cylindrical airbags are given a certain curvature, resulting in a curved spiderweb-like structure that ultimately forms a spherical satellite frame, improving its mechanical properties and further enhancing its overall robustness.

[0019] The present invention discloses an on-orbit manufacturing robot that can use a winding part to wind carbon fiber bundles around cylindrical airbags and weave multiple cylindrical airbags with carbon fiber bundles. Then, a curing part is used to heat and cure the carbon fiber bundles wound around the cylindrical airbags or the woven carbon fiber bundles, thereby completing the on-orbit manufacturing of satellite skeleton. Attached Figure Description

[0020] Figure 1 This is a schematic diagram illustrating the structural principle of the present invention;

[0021] Figure 2 This is a schematic diagram of the radial portion of the satellite skeleton of the present invention;

[0022] Figure 3 This is a schematic diagram of the single-helix latitudinal section of the satellite skeleton of the present invention;

[0023] Figure 4 This is a schematic diagram of the multi-helix latitudinal section of the satellite skeleton of the present invention;

[0024] Figure 5 This is a schematic diagram of the front view structure of the satellite skeleton of the present invention;

[0025] Figure 6This is a top view of the satellite skeleton structure of the present invention;

[0026] Figure 7 This is a schematic diagram of the on-orbit manufacturing robot of the present invention.

[0027] Explanation of reference numerals in the attached figures:

[0028] 101. Warp mandrel, 102. Positioning plate, 103. Weft section, 104. Warp section, 2. Storage compartment, 3. Spoke, 401. Winding section, 402. Curing section, 501. Traveling mechanism, 502. Swinging mechanism, 503. Reciprocating mechanism, 504. Discharge mechanism, 505. Ring arm, 6. Columnar airbag. Detailed Implementation

[0029] The following is in conjunction with the appendix Figure 1-7 The specific embodiments of the present invention will be described in detail below, but it should be understood that the scope of protection of the present invention is not limited to the specific embodiments. All other embodiments obtained by those skilled in the art based on the embodiments of the present invention without inventive effort are within the scope of protection of the present invention.

[0030] like Figure 1-7 As shown, the on-orbit manufacturing process for the satellite skeleton provided by this invention includes the following steps:

[0031] Multiple radial mandrels 101 are fabricated outside the positioning disk 102, and the multiple radial mandrels 101 are arranged radially with the positioning disk 102 as the center;

[0032] Carbon fiber bundles are woven or wound around each meridional mandrel 101, covering the meridional mandrel 101, and the meridional carbon fiber bundles covering the meridional mandrel 101 are cured to form the meridional portion 104 of the satellite skeleton.

[0033] Starting from the positioning disk 102, multiple meridional sections 104 are interwoven in a spiral shape using carbon fiber bundles, and the latitudinal carbon fiber bundles are then solidified to form the latitudinal section 103 of the satellite skeleton. The final satellite skeleton produced has a spider web-like structure.

[0034] The working principle of the above embodiments is briefly described below:

[0035] The positioning disk 102 can be launched into a predetermined location in space along with the satellite. Multiple warp mandrels 101 are then fabricated on the outside of the positioning disk 102 in space. These warp mandrels 101 are arranged radially around the positioning disk 102. Carbon fiber bundles are woven or wound around each warp mandrel 101, covering it. The covered warp carbon fiber bundles are then cured to form the warp section 104 of the satellite skeleton. Starting from the positioning disk 102, the carbon fiber bundles are spirally interwoven with the multiple warp sections 104 in the weft direction, and then cured to form the weft section 103 of the satellite skeleton. The final satellite skeleton has a spiderweb-like structure. Furthermore, the number of carbon fiber bundles wound on the warp mandrels 101 is more than four strands, resulting in a rigid, stable, balanced, and highly reliable spiral self-locking structure after the entire skeleton is cured.

[0036] The on-orbit manufacturing process for the satellite skeleton of the present invention can reduce the volume of the satellite skeleton components to be launched and weave satellite skeleton components of a predetermined size in orbit, thereby avoiding the size limitation problem of satellite skeleton components and the resulting vibration problem during satellite launch.

[0037] Based on the above embodiments, in order to form a stable and robust meridional component for the entire satellite frame.

[0038] like Figure 1-6 As shown, the manufacturing process of the plurality of meridional mandrels 101 is as follows: multiple tubular meridional mandrels 101 are printed on the outer edge of the positioning disk 102 by additive manufacturing, or multiple compressed cylindrical airbags 6 are set on the outer edge of the positioning disk 102, and air is filled into the multiple compressed cylindrical airbags 6 located in space, so that the multiple cylindrical airbags 6 are inflated and unfolded to form multiple meridional mandrels 101.

[0039] When manufacturing multiple meridional mandrels, two manufacturing processes can be used. The first process involves using a 3D printing robot to additively print multiple tubular meridional mandrels 101 on the outer edge of the positioning disk 102. The second process involves setting multiple compressed cylindrical airbags 6 on the outer edge of the positioning disk 102. Before satellite launch, the multiple cylindrical airbags 6 are compressed into the positioning disk 102 to reduce the overall volume of the structure, making it easier to transport into orbit by rocket. After the positioning disk 102 is launched into orbit with the satellite, the multiple compressed cylindrical airbags 6 are inflated, causing them to expand and arrange radially to form multiple meridional mandrels 101. Both processes are on-orbit manufacturing methods, further reducing the volume of the satellite skeleton during launch, and ultimately forming stable and robust meridional mandrels 101.

[0040] Based on the above embodiments, in order to improve the overall robustness and seismic resistance of the satellite frame.

[0041] like Figure 3 and 4 As shown, when multiple warp sections 104 are interwoven in the weft direction using carbon fiber bundles, multiple warp sections 104 need to be interwoven repeatedly in both forward and reverse directions so that the weft carbon fiber bundles present a concentric multi-helix structure.

[0042] By repeatedly weaving multiple warp sections 104 of carbon fiber bundles in both forward and reverse directions, the interwoven weft carbon fiber bundles can present a concentric multi-helix structure. The multi-helix structure has higher structural stability and reliability, thereby improving the overall strength and seismic resistance of the satellite frame.

[0043] As a preferred option, such as Figure 2 As shown, after the columnar airbag 6 is wrapped or woven with carbon fiber bundles, a hot gas flow is introduced into the columnar airbag 6 to heat and solidify the carbon fiber bundles. The solidification methods generally include thermosetting and photosetting. After the carbon fiber bundles are wrapped around the columnar airbag 6, hot gas is injected into the hollow columnar airbag 6 to heat the matrix material and accelerate solidification. The solidification process in the weft section 103 after the carbon fiber bundles are interwoven also employs thermosetting. Because heat dissipation is slow in the high vacuum environment, the energy consumption during carbon fiber bundle solidification is low, thereby reducing the energy consumption during the weaving of the entire satellite frame.

[0044] As a preferred option, such as Figure 1 , 2 As shown in Figures 4 and 5, the positioning disk 102 has a polygonal structure, with a storage compartment 2 at each vertex. Each storage compartment 2 contains a compressed cylindrical airbag 6. By setting the positioning disk 102 as a polygonal structure, after each compressed cylindrical airbag 6 is inflated, it is discharged from the storage compartment 2 at each vertex of the polygonal structure. One end of each cylindrical airbag 6 is connected to a vertex of the polygonal structure. After the multiple cylindrical airbags 6 are unfolded, the entire warp component forms a spoke-shaped structure 3, which facilitates the subsequent weft weaving of the multiple cylindrical airbags 6 using carbon fiber bundles.

[0045] As a preferred option, such as Figure 5 and 6 As shown, the positioning disk 102 has multiple spokes 3, with one end of each spoke 3 connected together, and the other end of each spoke 3 connected to a vertex of the positioning disk 102. By setting multiple spokes 3, with one end of each spoke 3 connected together, and the other end of each spoke 3 connected to a vertex of the polygonal positioning disk 102, the structural strength of the entire positioning disk 102 can be improved, thereby further enhancing the robustness and seismic resistance of the entire satellite frame.

[0046] As a preferred option, such as Figure 3 and 4 As shown, the columnar airbags 6 have a certain curvature, with the center of each columnar airbag 6 facing the central axis of the positioning disk 102. By giving the columnar airbags 6 a certain curvature, the woven spiderweb-like structure also has a certain curvature, resulting in a spherical satellite skeleton. This improves the mechanical properties of the satellite skeleton and further enhances the overall robustness of the satellite skeleton.

[0047] As a preferred option, such as Figure 5 and 6 As shown, the columnar airbag 6 is made of a thin film material. Using a thin film material to make the columnar airbag 6 reduces the overall weight of the satellite frame.

[0048] This invention also provides an on-orbit manufacturing robot, such as Figure 7 As shown, the robot is used to manufacture the warp section 104 and weft section 103 of the satellite skeleton. The robot includes a winding section 401 and a curing section 402. The curing section 402 is located behind the winding section 401. The winding section 401 is used to wind carbon fiber bundles around the warp mandrel 101 or to weave multiple warp sections 104 using carbon fiber bundles. The curing section 402 is used to heat-cur the warp or weft carbon fiber bundles. By using the winding section 401 to wind carbon fiber bundles around the warp mandrel 101 and to weave multiple warp mandrels 101 using carbon fiber bundles, and then using the curing section 402 to heat-cur the carbon fiber bundles wound around the warp mandrel 101 or the interwoven weft carbon fiber bundles, the on-orbit manufacturing of the satellite skeleton is completed.

[0049] As a preferred option, such as Figure 7 As shown, the winding section 401 includes a traveling mechanism 501, a swinging mechanism 502, and a reciprocating mechanism 503. The traveling mechanism 501 travels on multiple warp mandrels 101. A discharge mechanism 504 is provided on the traveling mechanism 501, containing carbon fiber bundle raw material. The carbon fiber bundle discharged from the discharge mechanism 504 passes through the swinging mechanism 502 and enters the reciprocating mechanism 503. The reciprocating mechanism 503 is equipped with a ring arm 505, which winds the carbon fiber bundle onto the warp mandrels 101. The traveling mechanism 501 travels on the multiple warp mandrels 101, and the carbon fiber bundle raw material is discharged from the discharge mechanism 504. The swinging mechanism 502 pulls the carbon fiber bundle, ensuring continuous output. The reciprocating mechanism 503 drives the ring arm 505 to reciprocate on the warp mandrels 101, thereby winding the carbon fiber bundle onto the warp mandrels 101 and ensuring the continuity of the carbon fiber bundle winding or weaving.

[0050] Although embodiments of the invention have been shown and described, it will be understood by those skilled in the art that various changes, modifications, substitutions and alterations can be made to these embodiments without departing from the principles and spirit of the invention, the scope of which is defined by the appended claims and their equivalents.

Claims

1. An on-orbit manufacturing process for a satellite skeleton, characterized in that, The fabrication is carried out on the positioning disk (102) launched into space orbit, including the following steps: Multiple meridional mandrels (101) are fabricated outside the positioning disk (102), and the multiple meridional mandrels (101) are arranged radially with the positioning disk (102) as the center; Carbon fiber bundles are woven or wound around each meridional mandrel (101), covering the meridional mandrel (101), and the meridional carbon fiber bundles covering the meridional mandrel (101) are cured to form the meridional part (104) of the satellite skeleton. Starting from the positioning disk (102), multiple meridional sections (104) are interwoven in a spiral shape using carbon fiber bundles, and the latitudinal carbon fiber bundles are solidified to form the latitudinal section (103) of the satellite skeleton. The final satellite skeleton has a spider web structure.

2. The on-orbit manufacturing process for the satellite skeleton as described in claim 1, characterized in that, The manufacturing process of the plurality of meridional mandrels (101) is as follows: a plurality of tubular meridional mandrels (101) are printed on the outer edge of the positioning disk (102) by additive manufacturing, or a plurality of compressed cylindrical airbags (6) are set on the outer edge of the positioning disk (102), and air is filled into the plurality of compressed cylindrical airbags (6) located in space, so that the plurality of cylindrical airbags (6) are inflated and unfolded to form a plurality of meridional mandrels (101).

3. The on-orbit manufacturing process for the satellite skeleton as described in claim 1, characterized in that, When using carbon fiber bundles to weave multiple warp sections (104) in the weft direction, multiple warp sections (104) need to be woven repeatedly in both forward and reverse directions so that the weft carbon fiber bundles present a concentric multi-helix structure.

4. The on-orbit manufacturing process for the satellite skeleton as described in claim 2, characterized in that, After the columnar airbag (6) is wrapped or braided with carbon fiber bundles, hot air is introduced into the columnar airbag (6) to heat and solidify the carbon fiber bundles.

5. The on-orbit manufacturing process for the satellite skeleton as described in claim 2, characterized in that, The positioning disk (102) has a polygonal structure. Each vertex of the positioning disk (102) is provided with a storage compartment (2), and each storage compartment (2) is provided with a compressed cylindrical airbag (6).

6. The on-orbit manufacturing process for the satellite skeleton as described in claim 5, characterized in that, The positioning disk (102) has multiple spokes (3), one end of the multiple spokes (3) is connected together, and the other end of each spoke (3) is connected to a vertex of the positioning disk (102).

7. The on-orbit manufacturing process for the satellite skeleton as described in claim 2, characterized in that, The columnar airbags (6) have a certain curvature, and the center of the arc of each columnar airbag (6) is oriented toward the central axis of the positioning disk (102).

8. The on-orbit manufacturing process for the satellite skeleton as described in claim 2, characterized in that, The columnar airbag (6) is made of a thin film material.

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