Split spacecraft and method for on-orbit assembly of very large antennas

Abstract

The application discloses a split spacecraft and an on-orbit assembling method of a super-large antenna. The split spacecraft is composed of at least two main force bearing frames, a load mounting assembly and a pressing and unlocking assembly, adopts a mortise and tenon connection structure and a hollow pillar design, realizes longitudinal locking and separation and transverse pressing and split separation, and is suitable for flexible modular transportation. The application also discloses an on-orbit assembling method of a super-large antenna. A carrier rocket transports a basic satellite and a split spacecraft, the split spacecraft transports antenna modules, and precise assembling of the antenna modules is completed by an assembling robot. The method effectively solves the problems of insufficient flexible antenna module transportation devices and lack of assembling methods in the on-orbit assembling process of the existing super-large modular antenna, and has the advantages of wide application range, strong universality, high expandability and the like.

Description

Technical Field

[0001] This application relates to the field of spacecraft technology, and in particular to a method for on-orbit assembly of a segmented spacecraft and an ultra-large antenna. Background Technology

[0002] Deployable space antennas, as key components for information acquisition in spacecraft, play a vital role in space communication, electronic reconnaissance, remote sensing, and navigation. With the continuous advancement of major projects such as deep space exploration, manned spaceflight, and space-based observation, my country's demand for large-aperture deployable space antennas is becoming increasingly urgent. Globally, ultra-large deployable space antennas in the hundreds of meters range have become a cutting-edge research topic of focus and competition among major spacefaring nations, and on-orbit assembly technology is considered the most promising approach to achieving this goal. Modular on-orbit assembly can not only effectively reduce manufacturing and launch costs but also simplify the planning of assembly missions, thus enabling the deployment of large-scale space antennas. Typically, large space payloads are launched into orbit by launch vehicles and then assembled in orbit; the transportation of large space payloads is based on on-orbit assembly. However, current research on the transportation issues during the on-orbit assembly of large space payloads remains insufficient and requires further exploration and improvement. Summary of the Invention

[0003] This application aims to address at least one of the technical problems existing in the prior art. This application provides a method for on-orbit assembly of a segmented spacecraft and an ultra-large antenna, which can fully utilize the available space in the launch vehicle fairing, resulting in higher launch efficiency and solving the problem of the lack of current on-orbit assembly methods for ultra-large antennas.

[0004] The segmented spacecraft according to the first aspect of this application includes:

[0005] At least two main load-bearing frames, each of which has a first connector on both sides of its lateral direction;

[0006] A load mounting assembly is disposed on the main load-bearing frame, and a load is mounted on the main load-bearing frame through the load mounting assembly;

[0007] A clamping and unlocking assembly is disposed on the main load-bearing frame;

[0008] The two main load-bearing frames are laterally connected by the first connector to form a segmented spacecraft. The two segmented spacecraft are longitudinally unlocked connected by the clamping and unlocking assembly to form a segmented spacecraft stack. The clamping and unlocking assembly is used to control the longitudinal locking and separation of the segmented spacecraft stack.

[0009] The segmented spacecraft according to the embodiments of this application has at least the following beneficial effects:

[0010] The segmented spacecraft of this application includes at least two main load-bearing frames, a payload mounting assembly, and a clamping and unlocking assembly. The main load-bearing frames support the required payloads, with each main load-bearing frame constituting one spacecraft segment. First connecting members are provided on both lateral sides of the main load-bearing frames, and two spacecraft segments are laterally connected via these first connecting members to form the segmented spacecraft. The payload mounting assembly is mounted on the main load-bearing frames and is used to mount the payloads onto them, allowing each spacecraft segment to carry its own payload. Two adjacent segmented spacecraft are stacked longitudinally to form a segmented spacecraft stack. The main load-bearing frames are equipped with clamping and unlocking assemblies, allowing the two segmented spacecraft to be longitudinally unlocked and connected via these assemblies. The clamping and unlocking assemblies control the longitudinal locking and separation of the segmented spacecraft stack. The payload can be mounted on the inner and outer sides of the main load-bearing frames via payload mounting plates, fully utilizing the available space in the launch vehicle fairing, maximizing space utilization, and increasing launch efficiency. After the segmented spacecraft stack reaches the preset position, the clamping unlocking component causes the segmented spacecraft to separate laterally from the segmented spacecraft stack. As the two spacecraft lobes in the segmented spacecraft separate laterally, the first longitudinal connecting piece also separates naturally, allowing the spacecraft to separate naturally.

[0011] According to some embodiments of this application, a second connector is provided on both longitudinal sides of the main load-bearing frame, and a hollow support column is also provided on the main load-bearing frame. The clamping and unlocking assembly is disposed in the hollow support column, and the clamping and unlocking assembly and the second connector cooperate to control the longitudinal locking and separation of the segmented spacecraft stack.

[0012] According to some embodiments of this application, the main load-bearing frame includes at least three structural plates. The main load-bearing frame is provided with a Type I main load-bearing frame and a Type II main load-bearing frame. A structural plate is provided on the first side of the hollow column of the Type I main load-bearing frame, and at least two structural plates are provided on the second side of the hollow column of the Type I main load-bearing frame. At least two structural plates are provided on the first side of the hollow column of the Type II main load-bearing frame, and a structural plate is provided on the second side of the hollow column of the Type II main load-bearing frame. The main load-bearing frames of a single segmented spacecraft are of the same type, while the main load-bearing frames of adjacent stacked segmented spacecraft are of different types. The hollow columns of adjacent stacked segmented spacecraft are aligned and connected by the clamping and unlocking components in the hollow columns.

[0013] According to some embodiments of this application, both the first connector and the second connector are configured as mortise and tenon connectors. A first protrusion is provided on the first side of the main load-bearing frame, and a first recess is provided on the second side of the main load-bearing frame to cooperate with the first protrusion. The two main load-bearing frames are laterally connected through the cooperation of the first protrusion and the first recess to form the segmented spacecraft. A second protrusion is provided on one longitudinal side of the main load-bearing frame, and a second recess is provided on the other longitudinal side of the main load-bearing frame to cooperate with the second protrusion. The clamping and unlocking assembly, the second protrusion, and the second recess cooperate to control the longitudinal locking and separation of the two segmented spacecraft.

[0014] According to some embodiments of this application, the first protrusion is configured as a right-angled trapezoidal tooth, and the second protrusion is configured as an isosceles trapezoidal tooth.

[0015] According to some embodiments of this application, the clamping unlocking assembly includes an unlockable component and a separation nut. The unlockable component is disposed on the central axis of the hollow support column, and the unlockable component is unlockably connected to the separation nut. The two segmented spacecraft are locked or separated by the cooperation of the unlockable component and the separation nut.

[0016] According to some embodiments of this application, mounting holes are provided on both the inner and outer sides of the main load-bearing frame, and the load mounting assembly includes a load mounting plate and fasteners. The load mounting plate is fixed on the inner and outer sides of the main load-bearing frame by the cooperation of the fasteners and the mounting holes, and the load is mounted on the load mounting plate.

[0017] The on-orbit assembly method for a super-large antenna according to the second aspect of this application, including the segmented spacecraft in the above embodiments, includes the following steps:

[0018] S1. Obtain the data required for assembly and transportation through transportation analysis methods;

[0019] S2. Assemble the segmented spacecraft according to the data;

[0020] S3, the first launch vehicle launches, transporting and assembling the basic satellite;

[0021] S4. The i-th launch vehicle is launched, and the (i-1)-th segmented spacecraft is transported.

[0022] S5, the separation and splitting of the j-th layer of the (i-1)th stack of the segmented spacecraft;

[0023] S6. The k-th antenna module of the j-th layer of the (i-1)-th stack is docked, deployed, and assembled.

[0024] According to some embodiments of this application, a vehicle analysis method is also included, the vehicle analysis method comprising:

[0025] Let the side length of the antenna module be... The height when folded is h The unfolding ratio is set to Therefore, the diameter of the convergence is ;

[0026] Let the number of antenna module layers be . m The number of antenna modules is n , m The effective aperture of the layer antenna module is: ,

[0027] The data required for assembly and transportation can be obtained using the following formula:

[0028]

[0029] in,

[0030] (a) Number of antenna modules: When the required effective aperture of the antenna plane is... D , When this is the case, it indicates the required number of antenna module layers. m Therefore, the required number of antenna modules ;

[0031] (b) Number of layers in a segmented spacecraft stack: Let the effective payload diameter of the launch vehicle be... The effective payload height is denoted as The split-type spacecraft is set as positive. c A polygon, denoted by its side length as . The maximum diameter is The height is Limited by the envelope, The number of layers in a segmented spacecraft stack ;

[0032] (c) Number of launch vehicles: The number of launch vehicles that can be carried by each side of a segmented spacecraft is... b ,but Let the number of antenna modules in a basic satellite antenna be... p Therefore, a certain number of launch vehicles are needed. .

[0033] According to some embodiments of this application, the specific steps of steps S1 to S6 are as follows:

[0034] S1-1. Based on the effective aperture requirement of the antenna satellite, calculate the number of antenna module layers m, the number of antenna modules n, the number of layers of the segmented spacecraft stack e, and the number of launch vehicles f using the aforementioned launch vehicle analysis method.

[0035] S2-1, The spacecraft lobes are connected by the first connector to form a split-lobed spacecraft;

[0036] S2-2, the segmented spacecraft is formed by stacking clamping and unlocking components to form a segmented spacecraft stack;

[0037] S2-3, the antenna module and other functional modules are mounted and fixed on the segmented spacecraft stack via the load mounting assembly;

[0038] S2-4, the segmented spacecraft stack is encapsulated at the bottom of the launch vehicle's fairing and is pressed and fixed by a pressing and unlocking assembly;

[0039] S3-1, the first carrier rocket launch, transport and assembly of the basic satellite;

[0040] S4-1, the i-th launch vehicle is launched, and the (i-1)-th segmented spacecraft is transported.

[0041] S4-2, the i-th launch vehicle enters the preset orbit, the clamping and unlocking component of the e-th layer of the (i-1)-th segmented spacecraft stack is unlocked, and the segmented spacecraft stack separates from the fairing of the launch vehicle;

[0042] S5-1, The clamping and unlocking components of the j-th layer of the (i-1)-th segmented spacecraft stack are unlocked, and the j-th layer of the segmented spacecraft separates from the segmented spacecraft stack;

[0043] S5-2. As the j-th layer of the split-type spacecraft separates laterally, the split-type spacecraft naturally separates longitudinally, splitting into two spacecraft lobes.

[0044] S5-3, the two spacecraft lobes fly to the parking position near the base satellite;

[0045] S6-1, the k-th antenna module of the j-th layer of the (i-1)-th segmented spacecraft stack is transported to the preset docking point;

[0046] S6-2, The detachable extendable arm of the antenna module unfolds and the wrapping tape is released to form an antenna deployment module;

[0047] S6-3. The assembly robot flies to the docking point and grabs the antenna deployment module;

[0048] S6-4, The detachable extendable arm and antenna deployment module can be unlocked and separated;

[0049] S6-5, The assembly robot grabs the antenna deployment module and flies to the assembly position;

[0050] S6-6, The assembly robot docks and assembles the antenna deployment module into the preset position of the basic satellite antenna;

[0051] First execute steps S1, S2, and S3, from , 1:e, Repeat steps S4 to S6. When the last iteration of step S6 ends, all antenna modules are assembled and the ultra-large satellite antenna is assembled.

[0052] The on-orbit assembly method for a super-large antenna according to the second aspect of this application has at least the following advantages:

[0053] The on-orbit assembly method for ultra-large antennas in this application includes steps S1 to S6. S1. Obtaining the data required for assembly and transportation through the aforementioned launch vehicle analysis method; S2. Assembling the segmented spacecraft; S3. Launching the first launch vehicle and transporting and assembling the basic satellite; S4. Launching the i-th launch vehicle and transporting the (i-1)-th segmented spacecraft stack; S5. Separating and segmenting the j-th layer of the (i-1)-th stack of segmented spacecraft; S6. Docking, deploying, and assembling the k-th antenna module of the j-th layer of the (i-1)-th stack. , 1: e, The process repeats steps S4 through S6. When step S6 of the final cycle ends, all antenna modules are assembled, forming an ultra-large satellite antenna. This application's on-orbit assembly method for ultra-large antennas fully utilizes the limited space within the launch vehicle fairing by employing a segmented spacecraft modular transport mechanism for flexible antenna modules and other functional modules, thereby significantly improving the payload ratio and reducing launch costs. Simultaneously, the clamping and unlocking assembly controls the layer-by-layer unlocking mechanism of the segmented spacecraft stack, ensuring the smooth and uniform separation of each layer of antenna modules, significantly reducing the risk of mechanical shock and stress concentration, and improving safety and assembly accuracy. The segmented spacecraft of this application possesses good versatility and scalability, allowing for flexible adjustment of the number and layers of antenna modules to meet the diverse assembly needs of hundred-meter-class ultra-large antenna systems, demonstrating significant engineering application value in terms of efficiency, reliability, and economy. Attached Figure Description

[0054] The present application will be further described below with reference to the accompanying drawings and embodiments, wherein:

[0055] Figure 1 This is a schematic diagram of the main load-bearing frame of a segmented spacecraft according to an embodiment of this application;

[0056] Figure 2 This is a structural example diagram of a segmented spacecraft according to an embodiment of this application;

[0057] Figure 3 This is a schematic diagram of the structure of the Type I main load-bearing frame of a segmented spacecraft according to an embodiment of this application;

[0058] Figure 4 for Figure 3 A structural schematic diagram of another embodiment from another angle;

[0059] Figure 5 This is a schematic diagram of the structure of the Type II main load-bearing frame of a segmented spacecraft according to an embodiment of this application;

[0060] Figure 6 for Figure 5 A structural schematic diagram of another embodiment from another angle;

[0061] Figure 7 This is a schematic diagram of the structure of a segmented spacecraft stack according to an embodiment of this application;

[0062] Figure 8 This is a schematic diagram of the structure of a segmented spacecraft stack according to another embodiment of this application;

[0063] Figure 9 This is a schematic diagram of the structure of a launch vehicle according to one embodiment of this application;

[0064] Figure 10 This is a schematic diagram of the structure of a launch vehicle carrying a segmented spacecraft stack according to an embodiment of this application;

[0065] Figure 11 This is a schematic diagram of the antenna deployment after the segmented spacecraft is segmented, according to one embodiment of this application.

[0066] Figure 12 This is a schematic diagram of an antenna deployment module for a grasping robot according to one embodiment of this application;

[0067] Figure 13 This is a schematic diagram of an ultra-large antenna according to an embodiment of this application;

[0068] Figure 14 This is a flowchart illustrating an on-orbit assembly method for an ultra-large antenna according to an embodiment of this application.

[0069] Figure label:

[0070] Main load-bearing frame 1; Type I main load-bearing frame 11; Type II main load-bearing frame 12; First connector 13; Second connector 14; Hollow column 15; First side of hollow column 151; Second side of hollow column 152; Mounting hole 16; First side 17; Second side 18; Third side 19; Fourth side 20;

[0071] Load mounting plate 21;

[0072] Antenna module 31; Separable extension arm 32; Other functional modules 33; Antenna deployment module 34; Covering strap 35;

[0073] Launch vehicle 4; fairing 41; fairing base 42; base connector 43; base satellite 44; assembly robot 45;

[0074] Split-type spacecraft stack 5; split-type spacecraft 51; spacecraft lobe 52. Detailed Implementation

[0075] The embodiments of this application are described in detail below. Examples of these embodiments are shown in the accompanying drawings, wherein the same or similar reference numerals denote the same or similar elements or elements having the same or similar functions throughout. The embodiments described below with reference to the accompanying drawings are exemplary and are only used to explain this application, and should not be construed as limiting this application.

[0076] In the description of this application, it should be understood that the use of terms such as "center," "middle," "longitudinal," "transverse," "length," "width," "thickness," "upper," "lower," "front," "rear," "left," "right," "vertical," "horizontal," "top," "bottom," "inner," "outer," "axial," "radial," and "circumferential" to indicate orientation or positional relationships based on the orientation or positional relationships shown in the accompanying drawings is solely for the convenience of describing this application and simplifying the description, and does not indicate or imply that the device or element referred to must have a predetermined orientation, or be constructed and operated in a predetermined orientation, and therefore should not be construed as a limitation of this application. Furthermore, features defined as "first" or "second" may explicitly or implicitly include one or more of that feature. In the description of this application, unless otherwise stated, "a plurality of" means two or more.

[0077] In the description of this application, it should be noted that, unless otherwise expressly specified and limited, the terms "installation," "connection," and "linking" should be interpreted broadly. For example, they can refer to a fixed connection, a detachable connection, or an integral connection; they can refer to a mechanical connection or an electrical connection; they can refer to a direct connection or an indirect connection through an intermediate medium; and they can refer to the internal connection between two components. Those skilled in the art can understand the specific meaning of the above terms in this application based on the specific circumstances.

[0078] The following reference Figures 1 to 14 This application describes the on-orbit assembly method of a segmented spacecraft and an ultra-large antenna in the embodiments of this application.

[0079] according to Figure 1 , Figure 2 , Figure 8 , Figure 9 and Figure 10As shown, one embodiment of this application of the segmented spacecraft 51 includes at least two main load-bearing frames 1, multiple load mounting assemblies, and at least two clamping and unlocking assemblies. Each main load-bearing frame 1 is a spacecraft segment 52. The main load-bearing frame 1 is used to carry various functional modules. First connecting members 13 are provided on both lateral sides of the main load-bearing frame 1. Two main load-bearing frames 1 are laterally connected via the first connecting members 13, and two spacecraft segments 52 are laterally connected via the first connecting members 13 to form a segmented spacecraft 51. The load mounting assemblies are disposed on the main load-bearing frames 1, and loads are mounted on the load mounting assemblies. The load mounting assemblies are used to mount loads onto the main load-bearing frames 1. The clamping and unlocking assembly is installed on the main load-bearing frame 1. Two adjacent segmented spacecraft stacks 5 are stacked to form a segmented spacecraft stack 5. Two adjacent segmented spacecraft 51 are connected in an unlockable manner through the clamping and unlocking assembly. The clamping and unlocking assembly controls the locking or separation of two adjacent segmented spacecraft 51. Two adjacent segmented spacecraft 51 are longitudinally locked together through the clamping and unlocking assembly to form a segmented spacecraft stack 5. The clamping and unlocking assembly is used to control the longitudinal locking and separation of the segmented spacecraft stack 5.

[0080] Two main load-bearing frames 1 are connected by a first connector 13, and two spacecraft lobes 52 are longitudinally connected by the first connector 13 to form a segmented spacecraft 51. The load mounting assembly is installed on the main load-bearing frames 1, and the load is mounted onto the load mounting assembly. The segmented spacecraft 51 is locked onto the base of the fairing 41 of the launch vehicle 4 by a clamping and unlocking assembly. After the launch vehicle 4 launches and reaches the preset position, the clamping and unlocking assembly controls the separation of the segmented spacecraft 51 from the fairing 41. As the segmented spacecraft 51 and the fairing 41 separate laterally, the first connector 13 also naturally separates, and the segmented spacecraft 51 separates into two spacecraft lobes 52.

[0081] The payload can be mounted on the inner and outer sides of the main load-bearing frame 1 using the payload mounting assembly, making full use of the available space in the fairing 41 of the launch vehicle 4, maximizing space utilization, and increasing launch efficiency. Different payload modules can be loaded onto the spacecraft lobe 52 using the payload mounting assembly. The antenna module 31 can be mounted on the outer side of the main load-bearing frame 1 using the payload mounting assembly, accommodating antenna modules 31 of various shapes and sizes, as well as the flexibility of the antenna. Through the configuration of the payload mounting assembly, other payloads, such as control modules, propulsion modules, power modules, integrated electronic modules, optical payload modules, data transmission modules, or other functional modules 33, can be mounted on the inner side of the main load-bearing frame 1. In traditional spacecraft, control modules, propulsion modules, and optical payload modules need to be mounted on the outer side of the spacecraft due to their structural characteristics and operating environment. In this application, because the spacecraft lobe 52 has two outer sides after being divided into lobe sections 51, these functional modules can be installed and fixed on the inner side of the lobe section 51 during transportation. This application improves space utilization while also greatly enhancing versatility.

[0082] The connection surfaces of multiple segmented spacecraft 51 and the connection surface between segmented spacecraft 51 and fairing base 42 are lateral separation surfaces, while the separation surfaces between spacecraft lobes 52 in a single segmented spacecraft 51 are longitudinal separation surfaces.

[0083] In some embodiments, there are six main load-bearing frames 1. Every two main load-bearing frames 1 are laterally connected by a first connector 13, and every two spacecraft lobes 52 are longitudinally connected by a second connector 14 to form a segmented spacecraft 51, thus forming three segmented spacecraft 51. The three segmented spacecraft 51 are locked together in pairs by clamping and unlocking components to form a segmented spacecraft stack 5. The segmented spacecraft 51 in contact with the fairing base 42 is also locked to the fairing base 42 by clamping and unlocking components. Various functional modules are mounted and fixed on the main load-bearing frames 1 by load mounting components. After the launch vehicle 4 carries the segmented spacecraft stack 5 and reaches the preset position, the clamping and unlocking components control the segmented spacecraft stack 5 to separate from the fairing 41, and the segmented spacecraft stack 5 separates from the launch vehicle 4. In the segmented spacecraft stack 5, the clamping and unlocking assembly of the first layer of segmented spacecraft 51 separates, causing the first layer of segmented spacecraft 51 to separate from the segmented spacecraft stack 5. As the lateral separation surface separates, the first connecting piece 13 of the longitudinal separation surface of the first layer of segmented spacecraft 51 naturally separates, resulting in the first layer of segmented spacecraft 51 splitting into two spacecraft lobes 52. Subsequently, the clamping and unlocking assembly of the second layer of segmented spacecraft 51 in the segmented spacecraft stack 5 separates, causing the second layer of segmented spacecraft 51 to separate from the segmented spacecraft stack 5. As the lateral separation surface separates, the first connecting piece 13 of the longitudinal separation surface of the second layer of segmented spacecraft 51 naturally separates, resulting in the second layer of segmented spacecraft 51 also splitting into two spacecraft lobes 52. Finally, the third layer of segmented spacecraft 51 also splits into two spacecraft lobes 52 due to the separation of its lateral separation surface and the natural separation of its longitudinal separation surface first connecting piece 13.

[0084] In some other embodiments, a single lobe spacecraft 51 is composed of three, four or more main load-bearing frames 1, that is, a single lobe spacecraft 51 is composed of two, three, four or more spacecraft lobes 52.

[0085] In some embodiments, each main load-bearing frame 1 includes multiple load mounting components, and each load mounting component may be equipped with one or more functional modules.

[0086] In some embodiments, each main load-bearing frame 1 is provided with a clamping and unlocking component. In other embodiments, each main load-bearing frame 1 is provided with multiple clamping and unlocking components.

[0087] In some embodiments, the main load-bearing frame 1 has four, eight, ten or more, that is, the spacecraft lobe 52 is provided with four, eight, ten or more, and every two spacecraft lobe 52 are connected laterally to form a lobe-type spacecraft 51, and multiple lobe-type spacecraft 51 are stacked and locked together longitudinally to form a lobe-type spacecraft stack 5.

[0088] In some embodiments, the first connector 13 is used to prevent the spacecraft lobe 52 in a single-lobe spacecraft 51 from moving relative to the longitudinal direction.

[0089] according to Figure 1 , Figure 2 , Figure 8 , Figure 9 and Figure 10 As shown, in one embodiment of this application, second connectors 14 are provided on both longitudinal sides of the main load-bearing frame 1. The second connectors 14 are used to connect two adjacent segmented spacecraft 51. The main load-bearing frame 1 is also provided with hollow pillars 15. The hollow pillars 15 of each segmented spacecraft 51 in the segmented spacecraft stack 5 are aligned and connected. The hollow pillars 15 are used to support the weight of all the segmented spacecraft 51 stacked on top. The clamping and unlocking assembly is located inside the hollow pillar 15. The clamping and unlocking assembly located inside the hollow pillar 15 can better save space and make full use of the effective space in the fairing 41. The clamping and unlocking assembly and the second connector 14 cooperate to control the lateral locking and separation of the segmented spacecraft stack 5. The cooperation of the clamping and unlocking assembly and the second connector 14 can better lock and fix two adjacent lateral spacecraft stacks.

[0090] Two main load-bearing frames 1 are connected by a first connector 13, and two spacecraft lobes 52 are laterally connected by the first connector 13 to form a segmented spacecraft 51. Based on the position of the hollow support column 15 of each segmented spacecraft 51, the hollow support columns 15 of adjacent segmented spacecraft 51 are aligned and then stacked longitudinally to form a segmented spacecraft stack 5. The adjacent segmented spacecraft 51 are longitudinally locked by the cooperation of a clamping unlocking component and a second connector 14, thus forming a segmented spacecraft stack 5. When the segmented spacecraft stack 5 reaches a preset position, the segmented spacecraft 51 from the first layer to the bottom layer separate sequentially. The clamping unlocking component of the first layer of segmented spacecraft 51 unlocks, and the second connector 14 also naturally separates, thus separating the first layer of segmented spacecraft 51 from the second layer of segmented spacecraft 51. As the first-layer segmented spacecraft 51 and the second-layer segmented spacecraft 51 separate laterally, the first connecting piece 13 of the first-layer segmented spacecraft 51 also naturally separates, and the first-layer segmented spacecraft 51 separates into two spacecraft lobes 52. Subsequently, the second-layer segmented spacecraft 51 and the bottom-layer segmented spacecraft 51 also separate sequentially in the same way. The segmented spacecraft stack 5 can be composed of multiple segmented spacecraft stacks 5 connected together.

[0091] In some embodiments, the hollow support 15 is made of ultra-high strength material, which enables it to better support all the segmented spacecraft 51 above, making the segmented spacecraft stack 5 more stable and safe.

[0092] In some embodiments, each main load-bearing frame 1 is provided with multiple hollow struts 15, and each hollow strut 15 is provided with a clamping and unlocking component, which can strengthen the lateral locking connection between adjacent segmented spacecraft 51, making the connection more stable. The arrangement of multiple hollow struts 15 can also strengthen the support strength of the segmented spacecraft 51 itself, better support the weight of the upper segmented spacecraft 51, and make it more stable.

[0093] In some embodiments, the second connector 14 is used to prevent two adjacent split spacecraft 51 from moving laterally relative to each other, and / or to prevent the split spacecraft 51 and the fairing base 42 from moving laterally relative to each other.

[0094] according to Figure 3 , Figure 4 , Figure 5 , Figure 6 , Figure 7 and Figure 8 As shown, in one embodiment of this application, the main load-bearing frame 1 includes at least three structural plates. These plates bear the weight of the segmented spacecraft 51 and its payload. The structural plates are connected at a certain angle to each other, and two or more main load-bearing frames 1 are connected in a closed manner. In the aerospace field, weight reduction is one of the key objectives of aerospace design. The structural plates have a hollow design and are equipped with multiple intersecting trusses, which effectively reduces the amount of material used. While increasing rigidity and strength, it also reduces weight, improves airflow within the segmented spacecraft stack 5, enhances heat dissipation, improves structural performance, and ensures the stable and safe operation of the spacecraft.

[0095] The main load-bearing frame 1 is provided with Type I main load-bearing frames 11 and Type II main load-bearing frames 12, which are divided into two types according to the position of the hollow pillars 15. The number of structural plates on both sides of the hollow pillars 15 of the Type I main load-bearing frame 11 is the opposite of the number of structural plates on both sides of the hollow pillars 15 of the Type II main load-bearing frame 12. The first side 151 of the hollow pillar of the Type I main load-bearing frame 11 has one structural plate, and the second side 152 of the hollow pillar of the Type I main load-bearing frame 11 has at least two structural plates. The first side 151 of the hollow pillar of the Type II main load-bearing frame 12 has at least two structural plates, and the second side 152 of the hollow pillar of the Type II main load-bearing frame 12 has one structural plate. The main load-bearing frames 1 in a single segmented spacecraft 51 are of the same type, that is, a single segmented spacecraft 51 is composed of two or more Type I main load-bearing frames 11 connected together, or a single segmented spacecraft 51 is composed of two or more Type II main load-bearing frames 12 connected together. In the segmented spacecraft stack 5, the main load-bearing frames 1 of adjacent stacked segmented spacecraft 51 are of different types. Taking a three-layer segmented spacecraft stack 5 as an example, the first layer of segmented spacecraft 51 consists of a type I main load-bearing frame 11, the second layer consists of a type II main load-bearing frame 12, and the third layer consists of a type I main load-bearing frame 11. Similarly, the type of main load-bearing frame 1 of each layer of segmented spacecraft 51 in the segmented spacecraft stack 5 can be interchanged. The multi-layer segmented spacecraft stack 5 is set up in the same way. The hollow struts 15 of adjacent stacked segmented spacecraft 51 are aligned and connected. Since the main load-bearing frames 1 of adjacent stacked segmented spacecraft 51 are of different types, the longitudinal separation surfaces of adjacent segmented spacecraft 51 are staggered. The staggered arrangement allows the longitudinal separation surfaces to restrain each other, reducing the likelihood of misalignment or slippage during launch and transportation, thus improving the overall structural stability and preventing structural failure due to excessive localized stress. When the segmented spacecraft stack 5 reaches its preset position and the segmented spacecraft 51 unlocks layer by layer, the staggered longitudinal separation surfaces allow each segmented spacecraft 51 to unlock gradually, rather than separating instantly as a whole, preventing the segmented spacecraft stack 5 from disintegrating and being damaged instantly by sudden impacts. The staggered arrangement of the longitudinal separation surfaces also allows the longitudinal separation surfaces to unlock synchronously when the segmented spacecraft 51 separates on the lateral separation surfaces, ensuring uniform separation of the two spacecraft lobes 52 and improving the controllability of the separation process.

[0096] In some embodiments, the main load-bearing frame 1 includes three structural plates connected at a 60-degree angle to each other. A single segmented spacecraft stack 5 includes three layers of segmented spacecraft 51, four Type I main load-bearing frames 11, and two Type II main load-bearing frames 12. The first layer of segmented spacecraft 51 is composed of two Type I main load-bearing frames 11 connected laterally via a first connector 13; the second layer of segmented spacecraft 51 is composed of two Type II main load-bearing frames 12 connected laterally via a first connector 13; and the third layer of segmented spacecraft 51 is composed of two Type I main load-bearing frames 11 connected laterally via a first connector 13. The hollow struts 15 of the first, second, and third layer of segmented spacecraft 51 are aligned and longitudinally stacked to form the segmented spacecraft stack 5. The clamping and unlocking components in the hollow struts 15 longitudinally lock adjacent segmented spacecraft 51, while the second connector 14 provides auxiliary connection between adjacent segmented spacecraft 51.

[0097] In some embodiments, the structural plates are connected by welding. In other embodiments, the structural plates in the main load-bearing frame 1 are integrally connected.

[0098] according to Figure 3 , Figure 4 , Figure 5 , Figure 6 , Figure 7 and Figure 8As shown, in one embodiment of this application, the first connecting member 13 of the main load-bearing frame 1 is configured as a first mortise and tenon connector, and the second connecting member 14 is configured as a second mortise and tenon connector. The first side 17 of the main load-bearing frame 1 is provided with a first protrusion, and the second side 18 of the main load-bearing frame 1 is provided with a first recess. The first protrusion and the first recess are detachably connected. At least two main load-bearing frames 1 are laterally connected through the cooperation of the first protrusion and the first recess to form a segmented spacecraft 51. The third side 19 of the main load-bearing frame 1 is provided with a second protrusion, and the fourth side 20 of the main load-bearing frame 1 is provided with a second recess. The second protrusion and the second recess are detachably connected. Two adjacent segmented spacecraft 51 are longitudinally connected through the second protrusion, the second recess, and the clamping and unlocking assembly to form a segmented spacecraft stack 5. The clamping and unlocking assembly, the second protrusion, and the second recess cooperate to control the longitudinal locking and separation of the two adjacent segmented spacecraft 51. The first connector 13, configured as a mortise and tenon joint, prevents longitudinal displacement of the two main load-bearing frames 1 when they are laterally connected. Similarly, the second connector 14, also configured as a mortise and tenon joint and staggered with the longitudinal separation surfaces of adjacent segmented spacecraft, prevents lateral displacement of the two main load-bearing frames 1 within the segmented spacecraft 51 when they are longitudinally locked together. Furthermore, the clamping and unlocking assembly clamps and locks adjacent segmented spacecraft 51, thus achieving a secure and stable overall structure for the segmented spacecraft stack 5. Both the first connector 13 and the second connector 14 are mortise and tenon joints, eliminating the need for metal bolts and reducing additional weight, which helps reduce transportation costs for the segmented spacecraft stack 5. The multiple mortise and tenon structures also distribute stress, ensuring the overall structural strength of the segmented spacecraft stack 5 while reducing weight, allowing it to withstand certain vibrations during transportation.

[0099] When three layers of segmented spacecraft 51 are stacked to form a segmented spacecraft stack 5, the two segments 52 of each layer of segmented spacecraft 51 are laterally connected by a first tenon-and-mortise connector to form a segmented spacecraft 51. The first tenon-and-mortise connector is used to prevent relative longitudinal displacement between the two segments 51 in a single segmented spacecraft 51. The third layer of segmented spacecraft 51 is locked to the fairing base 42 of the launch vehicle 4 by a clamping and unlocking assembly. The second recess of the second layer of segmented spacecraft 51 and the second protrusion of the third layer of segmented spacecraft 51 are tenon-and-mortise connected to prevent relative lateral displacement between the second and third layers of segmented spacecraft 51. At the same time, the second layer of segmented spacecraft 51 is longitudinally locked to the third layer of segmented spacecraft 51 by a clamping and unlocking assembly. The clamping and unlocking assembly, the first tenon-and-mortise connector, and the second tenon-and-mortise connector can make the structure of the entire segmented spacecraft stack 5 secure while reducing weight. The second recess of the first-layer segmented spacecraft 51 and the second protrusion of the second-layer segmented spacecraft 51 are joined by a tenon and mortise joint. Simultaneously, the first-layer segmented spacecraft 51 and the second-layer segmented spacecraft 51 are longitudinally locked together via a clamping and unlocking assembly, thus completing the assembly of the segmented spacecraft stack 5 with three layers of segmented spacecraft 51. The assembly of a segmented spacecraft stack 5 with multiple layers of segmented spacecraft 51 follows the same principle.

[0100] In some embodiments, the first and second tenon-and-mortise connectors of the main load-bearing frame 1 are provided in multiple ways, and the provision of multiple tenon-and-mortise connectors can make the overall structure of the segmented spacecraft stack 5 more stable.

[0101] according to Figures 1 to 10As shown, in one embodiment of this application, the second protrusion is configured as a right-angled trapezoidal tooth, the second recess is a groove that mates with the right-angled trapezoidal tooth, the first protrusion is configured as an isosceles trapezoidal tooth, and the first recess is a groove that mates with the isosceles trapezoidal tooth. The first protrusion being configured as an isosceles trapezoidal tooth allows the two spacecraft lobes 52 to better and more smoothly connect and separate during lateral connection or unlocking, reducing assembly difficulty. Because the isosceles trapezoidal teeth are symmetrical on both sides, the two spacecraft lobes 52 can be evenly stressed during lateral connection, reducing imbalance caused by installation deviations. The longitudinal separation surfaces are connected by isosceles trapezoidal teeth, and because adjacent longitudinal separation surfaces are staggered, the longitudinal separation surfaces of the split spacecraft 51 are locked and locked, and released and unlocked as the right-angled trapezoidal teeth of the lateral separation surface and the locking / unlocking assembly are connected. As the split spacecraft 51 separates on the lateral separation surface, the isosceles trapezoidal tooth tenon joint on the longitudinal separation surface will also naturally loosen and separate, thus allowing the two spacecraft lobes 52 to separate naturally. The mortise and tenon structure design eliminates the need for a separate, complex separation control mechanism, resulting in a compact structure that reduces overall complexity and manufacturing costs. It also reduces reliance on external drive or control systems, making it less susceptible to external interference or control errors, thus improving the reliability and simplicity of separation operations and enhancing the success rate and safety of on-orbit separation. The second protrusion, designed as a right-angled trapezoidal tooth, more effectively transfers and distributes vertical loads when adjacent segmented spacecraft are stacked, ensuring high compressive and separation resistance on the lateral separation surfaces during stacking. It also provides strong locking capabilities under stress, preventing displacement or misalignment due to vibration or impact during launch. The right-angled trapezoidal tooth also provides significant rigid support, improving the overall structural stability and safety.

[0102] In some embodiments, the fairing base 42 of the launch vehicle 4 is also provided with a base connector 43, which is a right-angled trapezoidal tooth and is tenon-jointed with the second recess of the bottom segmented spacecraft 51 to prevent the bottom segmented spacecraft 51 from being relatively laterally offset from the fairing base 42.

[0103] according to Figures 1 to 10As shown, in one embodiment of this application, the clamping and unlocking assembly includes an unlockable component and a separation nut. The separation nut is disposed at the top and bottom of the segmented spacecraft stack 5. The hollow support column 15 is a hollow cylinder. The unlockable component is disposed on the central axis of the hollow support column 15 and is positioned along the central axis of the hollow support column 15 of the main load-bearing frame 1. The unlockable component and the separation nut are unlockably connected, and the unlockable component and the separation nut cooperate to control the longitudinal locking and separation of adjacent segmented spacecraft 51. Through the cooperation of the unlockable component and the separation nut, a stable and tight mechanical connection can be formed between adjacent segmented spacecraft 51, ensuring that accidental separation will not occur due to vibration or impact during transportation and on-orbit operation, and that the connection can be quickly and safely released during separation. The unlockable component, disposed on the central axis of the hollow support column 15, enables the hollow support columns 15 of adjacent segmented spacecraft 51 to be stably aligned and connected, ensuring a good connection during locking and enhancing the stability of the overall structure.

[0104] In some embodiments, the unlockable component can be configured as a separable tension lock or an unlockable lever. The separable tension lock or unlockable lever is unlockably connected to the release nut, and the switching between the locked and unlocked states is achieved through a simple mechanical unlocking mechanism. This eliminates the need for overly complex drive mechanisms, simplifying the design of the segmented spacecraft stack 5 structure, reducing the overall weight of the structure, and providing effective protection for high load requirements.

[0105] according to Figures 1 to 10 As shown, in one embodiment of this application, mounting holes 16 are provided on both the inner and outer sides of the main load-bearing frame 1. The mounting holes 16 are evenly distributed around the perimeter of the structural plate. The load mounting assembly includes a load mounting plate 21 and fasteners. The load mounting plate 21 is fixedly mounted on the inner and outer sides of the main load-bearing frame 1 through the fasteners and mounting holes 16. The load is mounted on the load mounting plate 21 and then on the main load-bearing frame 1, achieving a stable connection between the load and the spacecraft lobe 52. This not only improves the overall structural rigidity of the system but also ensures that the load will not shift or loosen due to vibration or impact during launch and on-orbit assembly, thus improving safety. By using fasteners and mounting holes 16 to fix the load mounting plate 21, the assembly process is simplified. The design of the load mounting plate 21 provides a universal platform for fixing the load on the spacecraft lobe 52, which can be matched with functional modules of various types, sizes, and weights. The configuration can be flexibly adjusted according to mission requirements, greatly improving the versatility and assembly efficiency of the segmented spacecraft stack 5.

[0106] according to Figures 6 to 14As shown, the on-orbit assembly method for a super-large antenna in the second embodiment of this application includes an on-orbit assembly system comprising a launch vehicle 4, a base satellite 44, a segmented spacecraft 51, and an antenna module 31. The launch vehicle 4 is used to carry the segmented spacecraft 51 and the base satellite 44. The on-orbit assembly method for the super-large antenna includes the following launch analysis method:

[0107] Let the side length of antenna module 31 be... The height when folded is h The unfolding ratio is set to Therefore, the diameter of the convergence is ;

[0108] The antenna module has 31 layers. m The number of antenna modules 31 is n , m The effective aperture of the antenna plane of the layer antenna module 31 is ,

[0109] in

[0110]

[0111] (a) Number of antenna modules 31: When the required effective aperture of the antenna plane is... D , When this is the case, it indicates that the required number of antenna layers is... m Therefore, the required number of antenna modules is 31. ;

[0112] (b) The number of layers in the segmented spacecraft stack 5: Let the effective payload diameter of the launch vehicle 4 be... The effective payload height is denoted as The split-type spacecraft 51 is set as positive. c A polygon, denoted by its side length as . The maximum diameter is The height is Limited by the envelope, Then the number of layers in the segmented spacecraft stack 5 ;

[0113] (c) Launch vehicle quantity: The number of rockets that can be carried on each side of the segmented spacecraft 51 is... b ,but The basic satellite 44 antenna consists of 31 antenna modules. p Therefore, 4 launch vehicles are needed. .

[0114] If a satellite with a 100-meter antenna is required, then the effective diameter of the antenna plane is needed. Set the side length of antenna module 31 ; height of convergence ; folding ratio a =40; Closing diameter .

[0115] Effective aperture of the antenna plane of the 2-layer antenna module 31 (i.e., m=2) The effective aperture of the antenna plane of the 3-layer antenna module 31 (i.e., m=3) , Therefore, the required number of antenna layers is The required number of antenna modules is 31. .

[0116] Set the effective payload diameter of launch vehicle 4 The effective payload height is denoted as m The segmented spacecraft 51 is designed as a hexagonal prism, i.e. c =6, side length ,high Therefore, the number of stacking layers of the segmented spacecraft stack 5 =3, a segmented spacecraft stack 5 is composed of three segmented spacecraft stacks 5 stacked together.

[0117] The number of items that each side of the segmented spacecraft 51 can carry is set to... b =1, the number of antenna modules 31 that make up the basic satellite 44 antenna is 31. Therefore, 4 launch vehicles are needed. .

[0118] Therefore, by launching the aforementioned launch vehicle 4 at least twice, transporting 19 of the aforementioned antenna modules 31 and 1 basic satellite 44, a satellite with an aperture of approximately [missing information] can be assembled. A satellite with a 100-meter antenna.

[0119] according to Figures 6 to 14 As shown, in one embodiment of this application, the ultra-large on-orbit assembly method includes the following steps:

[0120] S1. Obtain the data required for assembly and transportation through transportation analysis methods;

[0121] S2. Assemble the segmented spacecraft according to the data;

[0122] S3, the first launch vehicle launches, transporting and assembling the basic satellite;

[0123] S4. The i-th launch vehicle is launched, and the (i-1)-th segmented spacecraft is transported.

[0124] S5, the separation and splitting of the j-th layer of the (i-1)th stack of the segmented spacecraft;

[0125] S6. The k-th antenna module of the j-th layer of the (i-1)-th stack is docked, deployed, and assembled.

[0126] according to Figures 6 to 14 As shown, in one embodiment of this application, the orbit assembly system further includes a detachable extension arm 32 and an assembly robot 45. The base satellite 44 is a conventional satellite, including a satellite shell, power system, propulsion system, control system, etc. The base satellite 44 carries a standard antenna consisting of a small number of antenna modules 31, an antenna extension arm, and the assembly robot 45. The base satellite antenna is stored using strapping. The segmented spacecraft 51 carries a large number of antenna modules 31. The antenna modules 31 are wrapped and stored using strapping 35 and securely mounted on the segmented spacecraft 51. The antenna modules 31 are structural unit modules of ultra-large antennas. The antenna modules 31 are connected to the segmented spacecraft 51 via the detachable extension arm 32. When the detachable extension arm 32 is locked, the antenna modules 31 are securely fixed to the payload mounting plate 21, ensuring stability during transportation and deployment. When antenna assembly is required, the detachable extension arm 32 is unlocked, separating the antenna modules 31 from the segmented spacecraft 51, allowing the assembly robot 45 to precisely grasp and install them at the target location.

[0127] The specific steps of steps S1 to S5 are as follows:

[0128] S1-1. Based on the effective aperture requirements of the antenna satellite, calculate the number of antenna module 31 layers m, the number of antenna modules 31 n, the number of layers of the segmented spacecraft stack 5 e, and the number of launch vehicles 4 f using the launch vehicle analysis method.

[0129] S2-1, the spacecraft lobe 52 is laterally connected by the first connector 13 to form a segmented spacecraft 51;

[0130] S2-2, two adjacent segmented spacecraft 51 are stacked together by a clamping and unlocking assembly to form a segmented spacecraft stack 5;

[0131] S2-3, the strap 35 houses the antenna module 31, the antenna module 31 is mounted on the payload mounting assembly via the split extension arm 32, and the antenna module 31 and other functional modules 33 are mounted and fixed on the segmented spacecraft stack 5 via the payload mounting assembly.

[0132] S2-4, the segmented spacecraft stack 5 is encapsulated at the bottom of the fairing 41 of the launch vehicle 4, and is pressed and fixed by the pressing and unlocking assembly;

[0133] S3-1, the first carrier rocket 4 was launched, which put the basic satellite 44 into orbit. The basic satellite antenna's envelope was unlocked and released, the basic satellite antenna was deployed, the antenna extension arm on the basic satellite 44 was deployed and locked, and the p antenna modules 31 located at the end of the antenna extension arm were deployed at the same time to form a standard-caliber antenna.

[0134] S4-1, the i-th carrier rocket 4 launches, and the (i-1)-th segmented spacecraft stack 5 transports it;

[0135] S4-2, the i-th launch vehicle 4 enters the preset orbit, the clamping and unlocking components of the e-th layer of the (i-1)-th segmented spacecraft stack 5 are unlocked, thereby separating the lateral separation surface of the e-th layer, and the segmented spacecraft stack 5 separates from the fairing 41 of the launch vehicle 4;

[0136] S5-1, the clamping unlocking assembly of the j-th layer of the segmented spacecraft 51 in the (i-1)-th segmented spacecraft stack 5 is unlocked, the unlockable part is unlocked and separated from the separation nut, and the j-th layer of segmented spacecraft 51 is separated from the segmented spacecraft stack 5.

[0137] S5-2. As the lateral separation surface of the j-th layer of the split spacecraft 51 separates, the longitudinal separation surface of the split spacecraft 51 naturally separates, and the split spacecraft 51 separates into two spacecraft lobes 52.

[0138] S5-3, with two spacecraft lobes 52 flying to their parking positions near the base satellite 44;

[0139] S6-1, the (i-1)th j-th layer k-th antenna module 31 is transported to the preset docking point;

[0140] S6-2, The wrapping tape 35 of the antenna module 31 is unlocked and released, the antenna module 31 is unfolded, and the separable extendable arm of the antenna module 31 is unfolded to form the antenna unfolding module 34.

[0141] S6-3, Assembly robot 45 flies to the docking point and grabs antenna deployment module 34;

[0142] S6-4, The separable extendable arm and antenna deployment module 34 can be unlocked and separated;

[0143] S6-5, Assembly robot 45 grabs antenna deployment module 34 and flies to the assembly position;

[0144] S6-6, Assembly robot 45 docks with antenna deployment module 34 and assembles it into the preset position of basic satellite 44 antenna;

[0145] In the on-orbit assembly method for ultra-large antennas, steps S1, S2, and S3 are performed first, from... , 1: e, Repeat steps S4 to S6. When the last iteration of step S6 ends, all antenna modules 31 are assembled and the ultra-large satellite antenna is assembled.

[0146] If it is necessary to assemble a satellite with a 100-meter antenna, that is, the effective diameter of the antenna plane... Set the side length of antenna module 31 ; height of convergence ; folding ratio a =40; Closing diameter Based on the payload analysis method, it was calculated that when the antenna module has 31 layers (m=3), This meets the requirements for satellites with 100-meter antennas. (Through...) That is, the required number of antenna modules 31 is With the effective payload diameter of launch vehicle 4 The effective payload height is denoted as m The segmented spacecraft 51 is designed as a hexagonal prism, i.e. c =6, side length ,high ,pass That is, the number of stacking layers of the segmented spacecraft stack 5. =3, a segmented spacecraft stack 5 requires three segmented spacecraft stacks 5 stacked together. The number of antenna satellites that each side of the segmented spacecraft 51 can carry is set to... b =1, the number of antenna modules 31 that make up the basic satellite 44 antenna is 31. ,pass That is, 4 launch vehicles are needed. One launch vehicle carries a basic satellite (44), and another launch vehicle carries a segmented spacecraft stack (5).

[0147] The three-tiered, segmented spacecraft 51 requires four Type I main load-bearing frames 11 and two Type II main load-bearing frames 12 (or two Type I main load-bearing frames 11 and four Type II main load-bearing frames 12). The two Type I main load-bearing frames 11 are laterally connected via isosceles trapezoidal tooth tenon-and-mortise connectors to form the third-tiered, segmented spacecraft 51. The two Type II main load-bearing frames 12 are laterally connected via isosceles trapezoidal tooth tenon-and-mortise connectors to form the second-tiered, segmented spacecraft 51. The hollow support column 15 of the second-tiered, segmented spacecraft 51 is aligned and connected with the hollow support column 15 of the third-tiered, segmented spacecraft 51. The second recess of the second-tiered, segmented spacecraft 51 and the right-angled trapezoidal tooth tenon-and-mortise connector of the third-tiered, segmented spacecraft 51 are longitudinally connected via tenon-and-mortise. The clamping and unlocking assembly of the second-tiered, segmented spacecraft 51 longitudinally locks and clamps the second-tiered, segmented spacecraft 51 and the third-tiered, segmented spacecraft 51. Two type I main load-bearing frames 11 are laterally snapped together by isosceles trapezoidal tooth tenon and mortise connectors to form the first layer of segmented spacecraft 51. The hollow pillar 15 of the first layer of segmented spacecraft 51 is aligned and connected with the hollow pillar 15 of the second layer of segmented spacecraft 51. The second recess of the first layer of segmented spacecraft 51 and the right-angled trapezoidal tooth tenon and mortise connector of the second layer of segmented spacecraft 51 are longitudinally tenon and mortise connected. The clamping and unlocking assembly of the first layer of segmented spacecraft provides longitudinal locking and clamping connection between the first layer of segmented spacecraft 51 and the second layer of segmented spacecraft 51, thus completing the assembly of a segmented spacecraft stack 5 composed of three layers of segmented spacecraft 51. The load mounting plate 21 is installed on the inner and outer sides of each main load-bearing frame 1 through fasteners and mounting holes 16. The antenna module 31 is installed on the load mounting plate 21 on the outer side of the main load-bearing frame 1, and other functional modules 33 are installed on the load mounting plate 21 on the inner side of the main load-bearing frame 1. The fairing base 42 of the launch vehicle 4 is provided with a base connector 43. The base connector 43 is mortised and tenoned with the second recess of the third-layer segmented spacecraft 51. The clamping and unlocking assembly of the third-layer segmented spacecraft 51 clamps and locks the third-layer segmented spacecraft 51 and the fairing base 42 longitudinally, so that the segmented spacecraft stack 5 is encapsulated on the fairing base 42 of the launch vehicle 4.

[0148] The first launch vehicle, rocket 4, launches, transporting the basic satellite 44 into the on-orbit assembly orbit of the ultra-large antenna. The antenna's wrapper is unlocked, the antenna deploys, and the antenna extension arm of the basic satellite 44 deploys and locks. Simultaneously, an antenna module 31 located at the end of the extension arm deploys, forming a standard-caliber antenna. The second launch vehicle, rocket 4, launches, transporting the segmented spacecraft stack 5 into its predetermined orbit. The unlockable components of the third-layer segmented spacecraft 51 of the segmented spacecraft stack 5 are released from the separation nut, allowing the third-layer segmented spacecraft 51 to separate from the third-layer lateral separation surface. The segmented spacecraft stack 5 separates from the fairing 41 of launch vehicle 4. The clamping unlocking assembly of the first-layer segmented spacecraft 51 unlocks, allowing the first-layer segmented spacecraft 51 to separate from the segmented spacecraft stack 5. As the lateral separation surface of the first-layer segmented spacecraft 51 separates, the first tenon joint of the longitudinal separation surface of the segmented spacecraft 51 naturally separates, and the segmented spacecraft 51 separates into two spacecraft lobes 52. The two spacecraft lobes 52 fly to the docking position of the base satellite 44. The first antenna module 31 of the first layer is transported to the preset docking point, the strap 35 of the antenna module 31 is unlocked and released, the antenna module 31 unfolds, and the detachable extendable arm of the antenna module 31 unfolds to form the antenna unfolding module 34. The assembly robot 45 flies to the docking point and grabs the antenna unfolding module 34. The detachable extendable arm unlocks and separates from the antenna unfolding module 34, and the antenna unfolding module 34 separates from the spacecraft lobe 52. The assembly robot 45 grabs the antenna unfolding module 34 and flies to the preset assembly position, docking and assembling the antenna unfolding module 34 into the preset position of the antenna of the base satellite 44. The second to sixth antenna modules 31 of the first layer are unfolded, transported and assembled in the same manner as the first antenna module 31 of the first layer. After the six antenna modules 31 of the first layer are assembled, the clamping and unlocking components of the second-layer segmented spacecraft 51 are unlocked, and the second-layer segmented spacecraft 51 separates from the segmented spacecraft stack 5. As the lateral separation surface of the second-layer segmented spacecraft 51 separates, the first tenon joint of the longitudinal separation surface of the segmented spacecraft 51 naturally separates, and the segmented spacecraft 51 separates into two spacecraft lobes 52. The six antenna modules 31 in the two spacecraft lobes 52 are assembled sequentially. Finally, the third-layer segmented spacecraft 51 also separates into lobes, and the six antenna modules 31 in the two spacecraft lobes 52 in the third-layer segmented spacecraft 51 are assembled sequentially. Finally, all antenna modules 31 are assembled, and the ultra-large satellite antenna assembly is completed.

[0149] This application provides a segmented spacecraft 51 for multi-module transportation. The segmented spacecraft 51 mainly consists of a main load-bearing frame 1, a payload mounting assembly, and a clamping and unlocking assembly. It can efficiently and safely transport antenna modules 31 and meet the requirements for on-orbit assembly of ultra-large antennas. The segmented spacecraft 51 not only improves the transportation efficiency of antenna modules 31 but also effectively solves the problem of the lack of transportation devices and methods for multiple flexible antenna modules 31 in the current on-orbit assembly of ultra-large antennas. The segmented spacecraft 51 of this application is applicable to flexible module transportation, compatible with antenna modules 31 and antenna assemblies of various sizes, and suitable for various on-orbit assembly requirements ranging from small antenna arrays to ultra-large antennas. The segmented spacecraft 51 can also be used to transport other types of functional modules, such as optical remote sensing equipment, communication relay modules, and power supply units, expanding the applicability of the spacecraft and improving its versatility. Adopting a modular design, it can be stacked in different numbers of layers according to mission requirements, forming either a single-layer segmented spacecraft 51 or a multi-layer segmented spacecraft stack 5, improving space utilization. A single segmented spacecraft 51 can be further segmented into multiple independent units, making the transportation mode more flexible and adaptable to payload requirements of different sizes and structures. Using the segmented spacecraft 51 of this application, multiple ten-meter-class antenna modules 31 can be transported in a single layer, and the carrying capacity of a single launch can be increased through multi-layer stacking. A single rocket launch can carry multiple segmented spacecraft 51, meeting the transportation requirements of antenna modules 31 needed to construct hundred-meter-class ultra-large antennas, significantly improving the transportation efficiency of on-orbit assembly, reducing the number of launches, and lowering the overall mission cost.

[0150] In the description of this specification, the use of terms such as "an embodiment," "some examples," "some embodiments," "illustrative embodiment," "example," "specific example," or "some examples" indicates that a specific feature, structure, material, or characteristic described in connection with that embodiment or example is included in at least one embodiment or example of this application. In this specification, the illustrative expressions of the above terms do not necessarily refer to the same embodiment or example. Furthermore, the specific features, structures, materials, or characteristics described may be combined in any suitable manner in one or more embodiments or examples.

[0151] The embodiments of this application have been described in detail above with reference to the accompanying drawings. However, this application is not limited to the above embodiments. Within the scope of knowledge possessed by those skilled in the art, various changes can be made without departing from the spirit of this application.

Claims

1. A segmented spacecraft, characterized in that: include At least two main load-bearing frames, each of which has a first connector on both sides of its lateral direction; A load mounting assembly is disposed on the main load-bearing frame, and a load is mounted on the main load-bearing frame through the load mounting assembly; A clamping and unlocking assembly is disposed on the main load-bearing frame; The two main load-bearing frames are laterally connected by the first connector to form a segmented spacecraft. The two segmented spacecraft are longitudinally unlocked connected by the clamping and unlocking assembly to form a segmented spacecraft stack. The clamping and unlocking assembly is used to control the longitudinal locking and separation of the segmented spacecraft stack. The main load-bearing frame is provided with second connectors on both longitudinal sides. The main load-bearing frame is also provided with hollow support columns. The clamping and unlocking assembly is located inside the hollow support columns. The clamping and unlocking assembly and the second connectors cooperate to control the longitudinal locking and separation of the segmented spacecraft stack. The main load-bearing frame includes at least three structural plates. The main load-bearing frame is provided with a Type I main load-bearing frame and a Type II main load-bearing frame. The Type I main load-bearing frame has one structural plate on the first side of its hollow support column and at least two structural plates on the second side. The Type II main load-bearing frame has at least two structural plates on the first side of its hollow support column and one structural plate on the second side. The main load-bearing frames of a single segmented spacecraft are of the same type, while the main load-bearing frames of adjacent stacked segmented spacecraft are of different types. The hollow support columns of adjacent stacked segmented spacecraft are aligned and connected via the clamping and unlocking components within the hollow support columns. Both the first and second connectors are mortise and tenon joints. The first side of the main load-bearing frame is provided with a first protrusion, and the second side of the main load-bearing frame is provided with a first recess that mates with the first protrusion. The two main load-bearing frames are laterally connected by the first protrusion and the first recess to form the segmented spacecraft. The longitudinal side of the main load-bearing frame is provided with a second protrusion, and the longitudinal side of the main load-bearing frame is provided with a second recess that mates with the second protrusion. The clamping and unlocking assembly, the second protrusion, and the second recess work together to control the longitudinal locking and separation of the two segmented spacecraft.

2. The segmented spacecraft according to claim 1, characterized in that: The first protrusion is configured as an isosceles trapezoidal tooth, and the second protrusion is configured as a right-angled trapezoidal tooth.

3. The segmented spacecraft according to claim 1, characterized in that: The clamping and unlocking assembly includes an unlockable component and a separation nut. The unlockable component is disposed on the central axis of the hollow support column, and the unlockable component is detachably connected to the separation nut. The two segmented spacecraft are locked or separated by the cooperation of the unlockable component and the separation nut.

4. The segmented spacecraft according to claim 1, characterized in that: Mounting holes are provided on both the inner and outer sides of the main load-bearing frame. The load mounting assembly includes a load mounting plate and fasteners. The load mounting plate is fixed on the inner and outer sides of the main load-bearing frame by the cooperation of the fasteners and the mounting holes, and the load is mounted on the load mounting plate.

5. A method for on-orbit assembly of an ultra-large antenna, comprising the segmented spacecraft as described in any one of claims 1 to 4, characterized in that: Includes the following steps: S1. Obtain the data required for assembly and transportation through transportation analysis methods; S2. Assemble the segmented spacecraft according to the data; S4. The i-th launch vehicle is launched, and the (i-1)-th segmented spacecraft is transported. S5, the separation and splitting of the j-th layer of the (i-1)th stack of the segmented spacecraft; S6. The k-th antenna module of the j-th layer of the (i-1)-th stack is docked, deployed, and assembled.

6. The on-orbit assembly method for an ultra-large antenna according to claim 5, characterized in that, It also includes a vehicle analysis method, which includes: Let the side length of the antenna module be... The height when folded is h The unfolding ratio is set to Therefore, the diameter of the convergence is ; Let the number of antenna module layers be . m The number of antenna modules is n , m The effective aperture of the layer antenna module is: , The data required for assembly and transportation can be obtained using the following formula: in, (a) Number of antenna modules: When the required effective aperture of the antenna plane is... D , When this is the case, it indicates the required number of antenna module layers. m Therefore, the required number of antenna modules ; (b) Number of layers in a segmented spacecraft stack: Let the effective payload diameter of the launch vehicle be... The effective payload height is denoted as The split-type spacecraft is set as positive. c A polygon, denoted by its side length as . The maximum diameter is The height is Limited by the envelope, The number of layers in a segmented spacecraft stack ; (c) Number of launch vehicles: The number of launch vehicles that can be carried on each side of a segmented spacecraft is... b ,but Let the number of antenna modules in a basic satellite antenna be... p Therefore, a certain number of launch vehicles are needed. .

7. The on-orbit assembly method for ultra-large antennas according to claim 6, characterized in that: The specific steps of steps S1 to S6 are as follows: S1-1. Based on the effective aperture requirement of the antenna satellite, calculate the number of antenna module layers m, the number of antenna modules n, the number of layers of the segmented spacecraft stack e, and the number of launch vehicles f using the aforementioned launch vehicle analysis method. S2-1, The spacecraft lobes are connected by the first connector to form a split-lobed spacecraft; S2-2, the segmented spacecraft is formed by stacking clamping and unlocking components to form a segmented spacecraft stack; S2-3, the antenna module and other functional modules are mounted and fixed on the segmented spacecraft stack via the load mounting assembly; S2-4, the segmented spacecraft stack is encapsulated at the bottom of the launch vehicle's fairing and is pressed and fixed by a pressing and unlocking assembly; S3-1, the first carrier rocket launch, transport and assembly of the basic satellite; S4-1, the i-th launch vehicle is launched, and the (i-1)-th segmented spacecraft is transported. S4-2, the i-th launch vehicle enters the preset orbit, the clamping and unlocking component of the e-th layer of the (i-1)-th segmented spacecraft stack is unlocked, and the segmented spacecraft stack separates from the fairing of the launch vehicle; S5-1, The clamping and unlocking components of the j-th layer of the (i-1)-th segmented spacecraft stack are unlocked, and the j-th layer of the segmented spacecraft separates from the segmented spacecraft stack; S5-2. As the j-th layer of the split-type spacecraft separates laterally, the split-type spacecraft naturally separates longitudinally, splitting into two spacecraft lobes. S5-3, the two spacecraft lobes fly to the parking position near the base satellite; S6-1, the k-th antenna module of the j-th layer of the (i-1)-th segmented spacecraft stack is transported to the preset docking point; S6-2, The detachable extendable arm of the antenna module unfolds and the wrapping tape is released to form an antenna deployment module; S6-3. The assembly robot flies to the docking point and grabs the antenna deployment module; S6-4, The detachable extendable arm and antenna deployment module can be unlocked and separated; S6-5, The assembly robot grabs the antenna deployment module and flies to the assembly position; S6-6, The assembly robot docks and assembles the antenna deployment module into the preset position of the basic satellite antenna; First execute steps S1, S2, and S3, from , 1:e, Repeat steps S4 to S6. When the last iteration of step S6 ends, all antenna modules are assembled and the ultra-large satellite antenna is assembled.

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