Satellite holder and design method adapted to an expandable communication capsule

Abstract

The application discloses a satellite holder suitable for an extensible communication cabin and a design method, relates to the field of communication satellite assembly, and comprises a south piece assembly, a north piece assembly, an upper trapezoidal beam assembly, a middle trapezoidal beam assembly, a lower trapezoidal beam assembly, a ground plate connecting piece, a horizontal plate connecting piece, a connecting device, a driving shaft system and a driven shaft system; the upper trapezoidal beam assembly, the middle trapezoidal beam assembly and the lower trapezoidal beam assembly are connected between opposite sides of the south piece assembly and the north piece assembly; a ground plate of the communication cabin is connected to the upper trapezoidal beam assembly through the ground plate connecting piece; and a horizontal plate of the communication cabin is connected to the lower trapezoidal beam assembly through the horizontal plate connecting piece; the connecting device is arranged on the inner side of the south piece assembly and connected with a south plate of the communication cabin; and the connecting device is arranged on the inner side of the north piece assembly and connected with a north plate of the communication cabin. The assembly precision of the extensible communication cabin is maintained.

Description

Technical Field

[0001] This invention relates to maintaining structural precision during the final assembly stage of aerospace communication satellites, specifically to a satellite retainer adapted to expandable communication modules, belonging to the field of precision assembly technology for satellite structural subsystems. Background Technology

[0002] The communication satellite has a rectangular box-shaped structure, mainly composed of a propulsion module and a communication module. According to the development process, final assembly is carried out after the structural components are assembled. During the final assembly phase, the propulsion module and communication module need to be disassembled, and equipment installation is carried out in both modules in parallel. The traditional Dongsi platform communication module mainly consists of a floor panel, south communication module panel, north communication module panel, south communication module bulkhead, and north communication module bulkhead, presenting an overall shape of… The structure is open at the bottom and lacks overall rigidity. If the communication compartment is directly divided, it will cause deformation or even damage to the communication compartment structure. Therefore, during the final assembly process, the communication compartment needs to be reinforced with retaining fixtures (hereinafter referred to as communication compartment retainers or retainers) to make it a closed rigid body.

[0003] The communication module retainer maintains the structural accuracy of the communication module throughout the assembly, placement, electrical testing, hoisting, flipping, and transportation processes. It also protects the north and south panels and OSR sheets on the outer surface of the communication module during these operations, until the communication module is successfully docked with the platform. A traditional communication module retainer typically consists of a south panel assembly, a north panel assembly, an east reinforcing beam assembly, a west reinforcing beam assembly, connectors to the satellite body, and a flipping and support shaft. The north and south panel assemblies protect the north and south panels, while the east and west reinforcing beam assemblies enclose the retainer as a single unit. The flipping and support shafts mesh with the drive shaft system of the flipping frame vehicle (and other supporting tooling), allowing the communication module to rotate axially during assembly and adapt to various assembly conditions. The traditional Dongsi platform communication module is relatively small, with no expansion plates on the outer panels and a lighter full-load weight. Therefore, the overall envelope size of the retainer is small, making its design and development less challenging and minimizing deformation of load-bearing components. However, with the increasing demand for communication satellite payloads, the Dongfeng-4 Extended and Dongfeng-4EII communication satellites have emerged. These satellites have added an extension module to the traditional configuration, increasing the overall height by 25% and making the contours of the extension plates on the floor and north and south sides more complex. This has become the mainstream platform (hereinafter referred to as the expandable communication module). The expandable communication module places higher demands on external dimensions, heavy-load eccentricity, full-load mass, and clearance space, thus posing a greater challenge to the deformation and load-bearing adaptability of the satellite cage. Summary of the Invention

[0004] The technical problem solved by this application is to overcome the shortcomings of the prior art and provide a satellite retainer that is adapted to the expandable communication cabin. The retainer body is made of standard aluminum alloy profile and is integrally formed by riveting process. The connection interface with the satellite has a certain degree of replaceability and adaptability. It is widely used to maintain the overall assembly accuracy of the expandable communication cabin.

[0005] The technical solution provided in this application is as follows:

[0006] A satellite retainer adapted to an expandable communication module includes a south panel assembly, a north panel assembly, an upper trapezoidal beam assembly, a middle trapezoidal beam assembly, a lower trapezoidal beam assembly, a floor connector, a horizontal plate connector, a connecting device, an active shaft system, and a driven shaft system. The south panel assembly and the north panel assembly are arranged opposite to each other, with the communication module located between them. The upper trapezoidal beam assembly, the middle trapezoidal beam assembly, and the lower trapezoidal beam assembly are connected between opposite sides of the south panel assembly and the north panel assembly. The floor of the communication module is connected to the upper trapezoidal beam assembly via the floor connector, and the horizontal plate of the communication module is connected to the middle trapezoidal beam assembly via the horizontal plate connector.

[0007] The south component has a connection device inside that connects to the south panel of the communication compartment; the north component has a connection device inside that connects to the north panel of the communication compartment.

[0008] The connecting device includes a primary connector and a secondary connector beam. The secondary connector beam is connected to the inside of the south component or the north component. The secondary connector beam is connected to one side of multiple primary connectors. The other side of the primary connector is connected to the south or north plate of the communication compartment.

[0009] The driving shaft system is located in the north segment of the module, and the driven shaft system is located in the south segment of the module.

[0010] The south panel component includes a frame crossbeam, a frame longitudinal beam, a connecting longitudinal beam, a short connecting crossbeam, and a short connecting longitudinal beam. Two frame crossbeams and two frame longitudinal beams are orthogonally arranged and connected sequentially to form the outer frame of the south panel component. Two connecting longitudinal beams are connected between two frame crossbeams. Multiple short connecting crossbeams are connected between two connecting longitudinal beams and between a connecting longitudinal beam and an adjacent frame longitudinal beam. Multiple short connecting longitudinal beams are connected between short connecting crossbeams between two connecting longitudinal beams and between a short connecting longitudinal beam and an adjacent frame crossbeam. A rotating shaft mounting plate is fixedly connected to the mounting frame formed by the short connecting crossbeams and short connecting longitudinal beams.

[0011] The structure of the north-side modules is the same as that of the south-side modules;

[0012] The shaft mounting plate of the north module is used to install the drive shaft system, while the shaft mounting plate of the south module is used to install the driven shaft system.

[0013] The south component connects two connecting devices.

[0014] The south component is also provided with inclined support beams, which include a first inclined beam, a second inclined beam and a third inclined beam;

[0015] The short connecting beams between the two connecting longitudinal beams are the top short connecting beam, the middle short connecting beam, and the bottom short connecting beam; the middle short connecting beam and the bottom short connecting beam connect the two short connecting longitudinal beams.

[0016] One end of the first inclined beam is connected to the intersection of the side frame beam and the connecting longitudinal beam, and the other end is connected to the middle of the top short connecting beam.

[0017] One end of the second inclined beam is connected to the intersection of the middle short connecting crossbeam and a short connecting longitudinal beam, and the other end is connected to the intersection of the lower short connecting crossbeam and the connecting longitudinal beam.

[0018] One end of the third inclined beam is connected to the intersection of the lower short connecting crossbeam and the connecting longitudinal beam, and the other end is connected to the intersection of the frame longitudinal beam and a short connecting crossbeam.

[0019] Both the driving shaft system and the driven shaft system include a rotating shaft, which is connected to a rotating shaft mounting plate. The rotating shaft and the rotating shaft mounting plate are connected by eight evenly distributed screws. Furthermore, two pins are provided between the rotating shaft mounting plate and the rotating shaft of the north component, and the two pins are symmetrically distributed on opposite sides of the rotating shaft.

[0020] The advantages of this invention compared to the prior art are:

[0021] (1) In the traditional cage installation process, the primary connectors are first installed on the north and south plates of the communication compartment. Due to the large number of connectors, it is difficult to adjust the flatness of the mounting surface formed by the connectors on the satellite. In addition, it is difficult to adjust the relative position of the holes of each connector. In this design, secondary connectors and adjusting shims are added. The relative accuracy of the primary connectors is adjusted in the ground small component state. Furthermore, the parallelism and flatness of the mounting surfaces on both sides are ensured through assembly processing. This not only ensures the installation accuracy but also greatly improves the efficiency of installation and adjustment.

[0022] (2) If the satellite connection point interface changes, the north and south cage components cannot be reused, resulting in high cost and poor flexibility. In this design, due to the addition of secondary connectors, only the secondary connection holes need to be remanufactured or modified, while the connection holes with the north and south cage components remain unchanged. Therefore, the adaptability of the cage is improved, and the modification difficulty and cost are reduced.

[0023] (3) Traditional processes use plate nuts to provide threaded connections at installation points. This is difficult to operate in deep cavity configurations with long pipe bodies, requiring special tools to install the plate nuts and drilling rivet connection holes, resulting in a large workload. In this design, the plate nuts are replaced with rivet nuts. The rivet nuts are installed at the pre-prepared connection holes, and the operation can be completed using a riveting process.

[0024] (4) The traditional design process is: mechanical configuration design → mechanical simulation analysis → overturning moment calculation. In the preliminary design of the overturning shaft position, the method of centering in the height direction is generally adopted. The final design is completed through multiple iterations of the above three steps. Therefore, since the consideration of full load and extreme working conditions is not reflected in the preliminary design parameters, the calculation results are often significantly different, resulting in many iterations and low design efficiency. In this design, the counterweight center of gravity balancing method is introduced, which incorporates the influence of full load and extreme working conditions into the configuration size design process. The grid beams around the shaft mounting plate are designed as a whole, which can realize rapid adjustment of the center of gravity and shorten the design reconstruction time.

[0025] (5) During the simulation process, an equivalent satellite model needs to be created to simulate the satellite's stiffness, center of mass, and mass. Traditional methods establish a simulation model based on the communication cabin outline and then adjust the center of mass and mass using an additional density method, which involves many iterations and often fails to achieve accurate simulation. This design proposes a density allocation method based on nonlinear programming theory, which uses the external outline dimensions as constraints and minimizes the deviation of the center of mass and mass as objectives to solve for the optimal density, resulting in significant improvements in accuracy and efficiency. Attached Figure Description

[0026] Figure 1 This is a flowchart illustrating the design process of the present invention.

[0027] Figure 2 Schematic diagram of the overall cage configuration;

[0028] Figure 3 Schematic diagram of the North and South sections;

[0029] Figure 4 Schematic diagram of trapezoidal beam assembly

[0030] Figure 5 This is a schematic diagram of the connecting components;

[0031] Figure 6 This is a schematic diagram of the connection components for the floor and level board;

[0032] Figure 7 Schematic diagram of the rotating shaft;

[0033] Figure 8 A schematic diagram showing the connection between the cage and the communication compartment;

[0034] Figure 9 This is a schematic diagram of the satellite coordinate system;

[0035] Figure 10 This is a structural schematic diagram of a certain primary connector.

[0036] Explanation of reference numerals in the attached diagram: 11. South section component; 12. North section component; 13. Upper trapezoidal beam component; 14. Middle trapezoidal beam component; 15. Lower trapezoidal beam component; 18. Primary connector; 19. Secondary connector beam;

[0037] 111. Driving shaft system; 112. Driven shaft system;

[0038] 21. Floor; 22. South panel of the communications compartment; 23. North panel of the communications compartment; 25. North bulkhead of the communications compartment; 26. Horizontal panel. Detailed Implementation

[0039] To make the objectives, technical solutions, and advantages of the present invention clearer, the embodiments disclosed in the present invention will be described in further detail below with reference to the accompanying drawings.

[0040] This application discloses a satellite retainer adapted to an expandable communication module for connecting the communication module. The communication module includes a floor 21, a south panel 22, a north panel 23, a south bulkhead, a north bulkhead 25, and a horizontal plate 26. The south panel 22 and the north panel 23 are parallel and each has one end connected to the floor 21. The horizontal plate 26 is disposed between the south panel 22 and the north panel 23. The south bulkhead is disposed inside the south panel 22, and the north bulkhead 25 is disposed inside the north panel 23.

[0041] like Figure 2 and Figure 8 As shown, the cage includes:

[0042] (1) Overall cage design, such as Figure 2 and Figure 3 As shown, the cage consists of the following parts: South panel assembly 11, North panel assembly 12, Upper trapezoidal beam assembly 13, Middle trapezoidal beam assembly 14, Lower trapezoidal beam assembly 15, floor connector, horizontal plate connector, primary connector 18, secondary connector 19, drive shaft system (including gears) 111, driven shaft system 112, lifting point screws, and rivets and screws between structures. The cage is connected to the south and north plates of the communication compartment via the primary connector using M5 screws. The secondary connector is installed on the outside of the primary connector, and the north and south panel assemblies are installed on the outside of the secondary connector, forming the main structure of the cage. Three sets of trapezoidal beam assemblies are installed in the east-west direction, connected to form a closed whole. The cage is connected to the floor connector via the floor connector and to the horizontal plate via the horizontal plate connector, with lateral connection points using M5 screws. The components of the cage are connected with M8 hexagon socket head cap screws; this error-proof design facilitates system operation and maintenance.

[0043] (2) The south and north components are installed on the ±Y sides of the satellite, respectively. They have basically the same configuration and are generally symmetrical about the XOZ reference plane of the satellite (specifically determined by whether the satellite outline is symmetrical). The main load-bearing beam is made of aluminum profile with a cross-section of 100×100mm, a wall thickness of 3.5mm, and grade LD31. Special corner connectors are used at the four corners, which not only achieve structural closure but also provide mounting holes for the lifting screws. The middle crossbeams and longitudinal beams are arranged orthogonally in a grid or T-shape. Polygonal reinforcing plates are set on the inner and outer surfaces of each intersection node, and reinforcing corner boxes are set in adjacent quadrant areas. The structural components are connected by riveting to improve the overall connection strength. A pivot mounting plate is set in the central part for installing the active / driven shaft, which will enable the cage and satellite to flip. The pivot mounting plate is connected to the four adjacent beams by screws.

[0044] The south component 11 includes a side frame crossbeam 111, a side frame longitudinal beam 112, a connecting longitudinal beam 113, a short connecting crossbeam 114, and a short connecting longitudinal beam 115. The two side frame crossbeams and the two side frame longitudinal beams are arranged orthogonally and connected sequentially to form the outer frame of the south component 11. The two connecting longitudinal beams are connected between the two side frame crossbeams. Multiple short connecting crossbeams are connected between the two connecting longitudinal beams and between the connecting longitudinal beams and adjacent side frame longitudinal beams. Multiple short connecting longitudinal beams are connected between the short connecting crossbeams between the two connecting longitudinal beams and between the short connecting crossbeams and adjacent side frame crossbeams. A pivot mounting plate is fixedly connected to the mounting frame formed by the short connecting crossbeams and the short connecting longitudinal beams.

[0045] (3) such as Figure 2 and Figure 4 As shown, the trapezoidal beam assembly (including upper trapezoidal beam assembly 13, middle trapezoidal beam assembly 14, and lower trapezoidal beam assembly 15) is installed on the ±X side of the satellite, with the upper trapezoidal beam located at the top (+Z direction) and the lower trapezoidal beam located at the bottom (-Z direction). The main structure of the trapezoidal beam is constructed using aluminum profiles with a cross-sectional dimension of 90×50mm, a wall thickness of 3mm, and grade LD31. The connection between the trapezoidal beam and the north and south slab assemblies is locally reinforced by riveting M8 sleeves. Polygonal reinforcing plates are installed on the inner and outer surfaces of the lap joints of each horizontal, longitudinal, and diagonal beam, and reinforcing corner boxes are installed in adjacent quadrant areas. The structural components are connected by riveting to improve the overall connection strength.

[0046] This embodiment provides the structure of the upper trapezoidal beam assembly 13, which includes a first horizontal beam 141, a first vertical beam 142 and a first inclined beam 143. The two first horizontal beams are parallel to each other, and three parallel first vertical beams are connected between the two first horizontal beams. The first horizontal beams and the first vertical beams form two frame-shaped parts. The first inclined beam is disposed within the frame-shaped part and is arranged diagonally.

[0047] (4) such as Figure 5As shown, the connecting assembly consists of a secondary connector and a primary connector, used to connect the four rows of tooling holes on the +Y and -Y plates of the communication compartment. The secondary connector uses LD31 aluminum profile with a cross-sectional dimension of 90×50mm and a wall thickness of 3mm. Two M8 nuts are riveted to the 90mm wide surface of the secondary connector's inner cavity, connecting it to the primary connector; a 4mm thick connecting plate is riveted to the other side. The flatness of the connection surface is ensured by using an integral assembly machining method. Two M8 nuts are riveted to one side of the secondary connector and the north and south panels, providing connection points for the corresponding hole sleeves of the north and south panel components. This method ensures the accuracy of the connection holes with the north and south panels while also enhancing the maintainability of the connecting assembly. The primary connector is milled from 2A12-H112 milling steel, and 0.1mm Teflon is adhered at the connection point between the primary connector and the north and south panels for isolation and protection.

[0048] Based on the specific connection positions on the communication module, the secondary connector and the primary connector are connected to form a single integral part, resulting in the connection assembly. When connecting the satellite retainer to the communication module, first connect the connection assembly to the corresponding positions on the south and north plates of the communication module, and then connect the south and north components to the connection assembly. During the process of connecting the south and north components to the connection assembly, only the primary connector's reference plane needs to be adjusted.

[0049] (5) such as Figure 6 As shown, the floor connector and horizontal plate connector are used to connect the cage and the communication compartment to the ±X side connection holes of the floor and horizontal plate. They are box-type structures made of aluminum alloy, with the material being 2A12H112. They are equipped with reinforcing ribs to improve overall rigidity.

[0050] (6) For example Figure 7 As shown, the rotating shaft is mounted on the rotating shaft mounting plates of the south and north segments of the cage, and docks with the tilting frame. It comes in two forms: an active end and a driven end. The active end (gear side) is mounted on the -Y side, and the driven end (rotating shaft) is mounted on the +Y side. The rotating shaft and the rotating shaft mounting plates on the north and south segments of the cage are connected by... The 90mm shaft end is positioned using 12.9 grade M16 screws. There are 8 screws on each side, evenly distributed. On a 125mm circle. Furthermore, to enhance the connection strength at the active end, two [unclear - possibly referring to components] are installed at the connection between the north-facing adapter plate and the drive shaft. 12mm pins, symmetrically distributed in On a 125mm circle. A transmission gear is installed on the active end shaft, which cooperates with the shaft system on the tilting frame to transmit torque and drive the cage to tilt. A sleeve is installed at the corresponding position on the passive end shaft, forming a rotating shaft system with the active end.

[0051] Example 1: Taking the design of a prototype communication compartment retainer as an example

[0052] Figure 1 The design process of the cage in this invention consists of 11 steps, such as... Figure 1 As shown, they are respectively:

[0053] (1) Defining the satellite coordinate system: The communication cabin structure adopts a local coordinate system. The origin of the coordinate system is located at the geometric center of the upper surface of the floor (X=0, Y=0, Z=5100, in the whole satellite mechanical coordinate system), and the +X, +Y, and +Z directions are the same as the whole satellite coordinate system. Figure 9 As shown, +Z is perpendicular to the floor, and +Y is the direction from the north panel of the communication cabin to the south panel of the communication cabin.

[0054] (2) Determine the maximum envelope dimensions of the ±X and ±Y sides of the cage: According to the technical requirements, the ±Y direction dimensions should meet the following conditions: ① The distance between the inner surface of the north and south plates and the outer surface of the north and south plates of the communication compartment is ≥60mm; ② The dimension of the traveling wave tube cooling head that needs to be avoided in the Y direction is ≥135mm on one side. Assuming that the distance between the outer surfaces of the north and south plates is 2100mm, the ±Y side dimensions of the cage are initially determined based on the above two points. (Thickness dimensions of the main beams in the north and south sections). According to technical requirements, the ±X direction dimension should be ≤3450mm. In order to ensure the effectiveness of the north and south sections in protecting the north and south slabs, the ±X direction dimension of the north and south sections should be as large as possible, and is initially set at 3440mm.

[0055] (3) Determine the dimensions of the primary connector: One side of the primary connector connects to the communication compartment, providing an M5 mounting countersunk hole; the other side connects to the secondary connecting beam, requiring two through holes. The specific dimensions need to be adjusted according to the hole positions on the structural plate (specific design will be carried out based on the specific dimensions of each satellite). For example... Figure 10 The diagram shown is a structural schematic of a primary connector.

[0056] (4) After connecting the primary connector to the threaded embedded part of the communication compartment, assemble the secondary connector beam of suitable length with the primary connector. Construct the hole positions for the support plate nuts on the secondary connector beam through the through holes of the primary connector. Assemble several sets of connecting pieces on the side where the secondary connector beam is installed with the north and south sections. In the actual assembly process, first lay the primary connectors out in a row on the assembly platform. After assembling and riveting to form the primary and secondary connector beams, as shown... Figure 5 As shown, one side of the connecting piece is processed to ensure that the parallelism of the upper and lower surfaces meets the requirements.

[0057] (5) Design preliminary models of the north and south sections and trapezoidal beam components: First, based on the ±X±Y side envelope dimensions determined in step (2), determine the outline dimensions of the south and north sections. Corner connectors (general-purpose parts) are used at the four corners, and the remaining main body is assembled using 100×100×3.5 aluminum square tubes with no outer rounded corners and inner rounded corners of R5. Based on the influence of the full load condition and the extreme condition on the overturning torque, the position of the rotating shaft mounting plate in the X and Z directions is calculated. A grid-shaped horizontal and vertical beam is arranged around the rotating shaft mounting plate, and two longitudinal beams are arranged at the positions where they connect with the first and second level connecting beams to form the main body of the north and south sections, such as Figure 3 As shown. After assembling the south and north components with the secondary connecting beam, upper, middle, and lower trapezoidal beam components in the ±X direction are designed under this envelope. The main body is assembled using 90×50×3 aluminum square tubes, without outer rounded corners, and with inner rounded corners of R5. The width of a single beam is equal to the ±Y direction dimension of the north and south components, and they are connected to each other by riveted M8 connecting sleeves. The height dimension design fully considers the following factors: ① the weight of a single component, ② the structural and working space dimensions for avoiding obstacles between components, ③ the upper and middle trapezoidal beams are connected to the satellite body through floor connectors and horizontal plate connectors, respectively. Therefore, the height dimension of the connectors needs to be reserved, such as... Figure 4 As shown.

[0058] (6) After the preliminary design is completed, the above parts / components are assembled with the communication cabin, the interference is checked, and the north and south components are reinforced with inclined beams according to the stress conditions. The reinforcement form and quantity are determined according to the weight margin.

[0059] (7) Connect the floor connector and the horizontal plate connector to the trapezoidal beam and the lateral embedded parts of the floor and horizontal plate respectively to form a closed configuration, such as Figure 2 As shown, changing the single-sided elongated oval hole design for the floor connector and the horizontal board connector to a double-sided vertical elongated oval hole design (i.e., one side of the empty space has a horizontal elongated oval hole, and the other side has a vertical elongated oval hole) can accommodate deviations in two orthogonal directions.

[0060] (8) Based on the equivalent model used in the satellite structural plate profile design calculation, nonlinear programming theory is used to assign a distributed load density to the structural plate (not limited to Excel, MATLAB, and other software toolboxes) to simulate the full-load mass and center of mass of the satellite assembly. The elastic modulus of aluminum alloy material is 71 GPa. The elastic modulus of the equivalent structural plate material is set to 50 GPa, which is slightly smaller than the product while being close to the actual performance of the product. This ensures that the equivalent model is not treated as a rigid body, thus avoiding distortion of the results.

[0061] (9) According to the technical requirements, analyze the following working conditions of the cage: ① +Z direction vertically upward (the cage is in a vertical parking state on the tilting frame car), ② ±X direction vertically upward (the cage is in a horizontal parking state on the tilting frame car), ③ vertical lifting, ④ horizontal lifting, ⑤ horizontal transportation. The simulation process is as follows: ① Define the material and assign material properties to the cage and the simulated satellite according to the material parameters determined in step (8). ② Perform finite element analysis on the model. The software used in this example is ANSYSworkbench18.2. Mesh the structure. The mesh type is AUTO and the mesh size is 20mm. ③ Apply an acceleration environment. When the satellite is parked and lifted on the vehicle, a downward acceleration of 1.3g (overload acceleration) is applied. During transportation, the satellite is in a horizontal state. After shock absorption (up and down vibration), the acceleration is 0.6g. After being superimposed with the gravity deceleration, it is 1.6g. Considering 1.3 times the overload, it is 2.08g. The acceleration in the horizontal direction (vehicle travel direction) is 1g. Considering 1.3 times the overload, it is 1.3g. Therefore, an acceleration vector superimposed in two directions is applied. ④ Apply constraints: When parked on the tilting frame, the constraint area is the curved surface on the rotating shaft mounting plate that mates with the rotating shaft; during lifting, the constraint area is the set of curved surfaces of the lifting point mounting holes; during transportation, the constraint area is the curved surface of the longitudinal beams on the ±X side of the north and south component panels. ⑤ Simulation results: Through finite element analysis, the maximum deformation and maximum stress are observed for each working condition. The maximum deformation in each direction is required to be ≤1mm, and the maximum stress should meet a safety factor of 3. The yield strength of aluminum alloy is 170MPa, therefore the maximum stress should be ≤56.7MPa. If these requirements are not met, local reinforcement is needed based on the weak points. Common reinforcement methods include adding inclined beam supports, adding fixed corner box parts, etc., and then recalculating and iterating until the requirements are met. Due to the increased connection size between the structural body and the cage, the stiffness decreases. Therefore, the 50mm mesh size is changed to 20mm during the simulation to more clearly represent the details of the deformation.

[0062] (10) Calculate the system overturning moment: It is necessary to check the overturning moment of the satellite and cage system. It is known that the driving moment of the overturning cage vehicle is ≥2600N.m for system alarm and ≥3000N.m for system shutdown. Therefore, the overturning moment of the satellite and cage system should be ≤2600N.m. The verification process is as follows: ① For the empty cabin state (after the structure is delivered, but the load has not yet been installed), the mass and center of gravity of the cage can be read from the cage model. The designer has given the mass and center of gravity of the empty cabin. The communication cabin coordinate system is translated to the height of the center of the overturning axis, and a new overturning coordinate system C1 is established. The coordinate axis direction remains unchanged. A virtual counterweight mass is introduced to adjust the overturning moment. It is generally located at the top or bottom of the cage. Update the coordinate values ​​of the cage and the satellite in the C1 coordinate system according to the center of gravity calculation formula. , m 1 indicates cage mass.r 1 represents the coordinate value of the holder on the X-axis. m 2 indicates the satellite's empty space mass. r 2 represents the X-axis coordinate value of the satellite's empty cabin status. m 3 represents the virtual counterweight mass. r 3 represents the X-axis coordinate value of the virtual counterweight. R x For the combined centroid coordinates of the satellite and cage system on the X-axis, similarly... R z Here are the combined centroid coordinates of the satellite and cage system on the Z-axis. Since the system rotates about the Y-axis, no calculation is required. R y System eccentric moment , m This refers to the system mass, specifically the total mass of the satellite and its cage. g It is the acceleration due to gravity. L As the lever arm, ,if If the (capacity coefficient) is met, the system can be flipped; if the flipping condition is not met, adjustments can be made. m The value of 3 is used for torque correction. The above steps are followed to check the full-load state (all loads assembled) and the ultimate state (loads concentrated in a certain direction). If the requirements are not met, the following measures can be taken: ① Analyze the torque direction and counterweight installation points, and compensate for the center of gravity by applying counterweights. This method generally requires a combined counterweight mass ≤120kg; otherwise, it is difficult to implement. ② Rebalance the center of gravity by reselecting the tilting shaft position. Each shaft mounting plate has five mounting holes (top, bottom, left, right, and center), with a 175mm distance between adjacent holes, thus compensating for larger torques. Recheck the tilting torque according to the previous steps. ③ Iteratively modify the model, adjusting the shaft mounting plate position to adapt to the center of gravity.

[0063] (11) Complete the full model design: After the mechanical analysis in step (9) and the torque check in step (10) meet the requirements, the structural model is refined, including details such as reinforcing plates, reinforcing corner boxes, and hole sleeves. According to GB / T3098.1-2010 "Mechanical Properties of Fasteners - Bolts, Screws and Studs", the yield strength of an M12 steel screw with a performance grade of 12.9 is 1080MPa. According to the third strength theory, the allowable shear stress of the screw is 216MPa. The minor diameter d of the screw is 10.1mm. Substituting d into the following formula, the allowable stress F value of the screw can be obtained:

[0064]

[0065] Therefore, under the allowable stress, the torque that the group of 8 M12 screws can withstand is:

[0066] T max =8×16.665×103×(140 / 2)×10 -3 =9332 N.m> M max =2600 N·m (maximum eccentric moment under all operating conditions, 1.3 times overload), 8 M12 screws are sufficient. To ensure the shear strength of the screws, 2 shear pins are added to the driving end for reinforcement. The following tests, including but not limited to, should be proposed for the cage:

[0067] 1) Communication Module Docking Test: ① Test Procedure: Fabricate a communication module simulation, ensuring the external interface dimensions match the actual communication module; install the communication module retainer and verify the interface dimensions; assemble the communication module simulation onto the retainer, and adjust the total mass of the simulation to 1750±50kg; install the support shaft and tilting shaft to the connecting holes on the south and north sections of the retainer (five sets in total, all requiring verification), ensuring insulation between the retainer and the frame during operation; install counterweights of different weights at the lower ends of the south and north sections. ② Test Result Evaluation: The retainer and communication module docking operation must be convenient and reliable; the docking dimensions on the retainer must allow for a 2mm adjustment margin; the rotating shaft must accurately match the five holes on the south and north sections; the rotating shaft installation and operation must be convenient, with no significant gaps between the shafts; the counterweight installation and operation must be convenient and reliable.

[0068] 2) Cage Precision Retention Test: ① Test Procedure: Assemble the communication cabin simulator onto the cage, add counterweights to the simulator to make its total mass 1750±50kg; elevate the bottom of the simulator, suspending the cage; install dial indicators at the four corners of the bottom of the simulator, with the indicator heads in contact with the corresponding positions at the four corners of the bottom of the cage, ensuring that deformation in the X, Y, and Z directions at each corner is measured; suspend the cage with the simulator, level the bottom of the cage, suspending the simulator so that its weight is evenly distributed on the cage, and observe the deformation shown by the dial indicator. ② Test Result Evaluation: The deformation of the cage should be within the allowable range of the test requirements.

[0069] 3) No-load and full-load hoisting, rotation, and lifting tests: ① Test procedure: Raise the gantry tilting system to its highest point; hoist the cage onto the gantry; verify the cage's flexibility and reliability during tilting (both electric and manual); verify its reliable positioning after tilting; verify the flexibility and reliability of lifting; verify its reliable self-locking after lifting; verify the timeliness and effectiveness of emergency stop; interfere with unilateral movement to verify whether the other side stops operation promptly after a unilateral failure. ② Test result evaluation: The cage's tilting, rotation, and lifting are flexible and reliable.

[0070] This completes the design of a satellite holder that can be adapted to a scalable communication cabin.

[0071] The contents not described in detail in this application specification are common knowledge to those skilled in the art.

[0072] The present application has been described in detail above with reference to specific embodiments and exemplary examples; however, these descriptions should not be construed as limiting the present application. Those skilled in the art will understand that various equivalent substitutions, modifications, or improvements can be made to the technical solutions and implementation methods of the present application without departing from the spirit and scope of the present application, and all such modifications and improvements fall within the scope of the present application. The scope of protection of the present application is determined by the appended claims.

Claims

1. A satellite holder adapted to an expandable communication module, characterized in that: It includes a south section assembly (11), a north section assembly (12), an upper trapezoidal beam assembly (13), a middle trapezoidal beam assembly (14), a lower trapezoidal beam assembly (15), floor connectors, horizontal plate connectors, connecting devices, a drive shaft system (111), and a driven shaft system (112); The south component (11) and the north component (12) are arranged opposite to each other. The communication compartment is located between the south component (11) and the north component (12). The upper trapezoidal beam assembly (13), the middle trapezoidal beam assembly (14) and the lower trapezoidal beam assembly (15) are connected between the opposite sides of the south component (11) and the north component (12). The floor panel (21) of the communication compartment is connected to the upper trapezoidal beam assembly (13) through the floor panel connector. The horizontal plate (26) of the communication compartment is connected to the middle trapezoidal beam assembly (14) through the horizontal plate connector. The south component (11) is provided with a connecting device on its inner side that connects to the south plate (22) of the communication compartment; the north component (12) is provided with a connecting device on its inner side that connects to the north plate (23) of the communication compartment. The connecting device includes a primary connector (18) and a secondary connector (19). The secondary connector (19) is connected to the inside of the south component (11) or the inside of the north component (12). The secondary connector (19) connects to one side of multiple primary connectors (18). The other side of the primary connector (18) is connected to the south plate (22) or the north plate (23) of the communication compartment. The drive shaft system (111) is located on the north segment assembly (12), and the driven shaft system (112) is located on the south segment assembly (11).

2. A satellite retainer adapted to an expandable communication cabin according to claim 1, characterized in that: The south component (11) includes a side frame beam, a side frame beam, a connecting beam (113), a short connecting beam (114), and a short connecting beam (115). The two side frame beams and the two side frame beams are arranged orthogonally and connected in sequence to form the outer frame of the south component (11). The two connecting beams are connected between the two side frame beams. Multiple short connecting beams are connected between the two connecting beams and between the connecting beams and the adjacent side frame beams. Multiple short connecting beams are connected between the short connecting beams between the two connecting beams and between the short connecting beams and the adjacent side frame beams. The mounting frame formed by the short connecting beams and the short connecting beams is fixedly connected to a rotating shaft mounting plate. The structure of the north component (12) is the same as that of the south component (11); The rotating shaft mounting plate of the north component (12) is used to install the drive shaft system (111), and the rotating shaft mounting plate of the south component (11) is used to install the driven shaft system (112).

3. A satellite holder adapted to an expandable communication cabin according to claim 2, characterized in that: The south component (11) connects two connecting devices.

4. A satellite holder adapted to an expandable communication cabin according to claim 3, characterized in that: The south component (11) is also provided with a diagonal support beam, which includes a first diagonal beam, a second diagonal beam and a third diagonal beam; The short connecting beams between the two connecting longitudinal beams are the top short connecting beam, the middle short connecting beam, and the bottom short connecting beam; the middle short connecting beam and the bottom short connecting beam connect the two short connecting longitudinal beams. One end of the first inclined beam is connected to the intersection of the side frame beam and the connecting longitudinal beam, and the other end is connected to the middle of the top short connecting beam. One end of the second inclined beam is connected to the intersection of the middle short connecting crossbeam and a short connecting longitudinal beam, and the other end is connected to the intersection of the lower short connecting crossbeam and the connecting longitudinal beam. One end of the third inclined beam is connected to the intersection of the lower short connecting crossbeam and the connecting longitudinal beam, and the other end is connected to the intersection of the frame longitudinal beam and a short connecting crossbeam.

5. A satellite holder adapted to an expandable communication cabin according to claim 2, characterized in that: Both the driving shaft system (111) and the driven shaft system (112) include a rotating shaft. The rotating shaft is connected to the rotating shaft mounting plate. The rotating shaft and the rotating shaft mounting plate are connected by eight evenly distributed screws. Two pins are provided between the rotating shaft mounting plate of the north component (12) and the rotating shaft. The two pins are symmetrically distributed on opposite sides of the rotating shaft.

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