Frame flat plate satellite structure based on extrusion and sheet metal forming

Abstract

The invention provides a frame flat plate satellite structure based on extrusion and sheet metal forming, and belongs to the field of satellite structure design. According to the satellite structure, modular and standardized design thoughts are adopted for the connecting columns, the cabin body, the frame, the cross beams and the connecting pieces, low-cost and high-efficiency mature forming process means such as extrusion and sheet metal are adopted for components, machining work is greatly reduced, the production cost is effectively reduced, and the production efficiency is improved. According to the satellite structure, splicing and inserting type assembly of products is facilitated through standardized interfaces of parts, flexible adaptability of configuration and load installation is achieved through modular design, and adaptability of the satellite structure to batch and low-cost development is achieved.

Description

Technical Field

[0001] The invention belongs to the technical field of satellite structure design, and in particular relates to a frame flat-panel satellite structure based on extrusion and sheet metal forming. Background Art

[0002] At present, the construction of massive satellite constellations represented by Starlink satellites is developing rapidly. Such satellites are mainly flat-plate configurations, and are launched in a stacked manner. Flat-plate satellite structures mostly adopt the molding method of integral die-casting of the main structure. This method has high requirements on the cost of die-casting machine molding equipment and molds. It is not conducive to reducing costs and has insufficient adaptability for the construction of satellite constellations with slightly lower batches and frequently changing configurations and payloads. In order to improve competitive advantages and adapt to the mission requirements of the construction of massive satellite constellations in various fields, it is necessary to develop a flat-plate satellite structure that can be produced in large quantities at low cost and efficiently, while also being adaptable to multiple configurations and payloads. Summary of the invention

[0003] In order to overcome the shortcomings of the prior art, the present invention provides a frame flat-panel satellite structure based on extrusion and sheet metal forming, which utilizes the high-efficiency approach forming characteristics of the extrusion process, uses standardized cross-section extruded profiles to quickly form the satellite main structure, and reduces machining work. Through modular assembly, the configuration adaptability is improved. It can be highly compatible with standardized assembly lines, reducing assembly work.

[0004] The above-mentioned purpose of the present invention is mainly achieved through the following technical solutions:

[0005] A frame flat-panel satellite structure based on extrusion and sheet metal forming comprises connecting columns and a structural main body flat plate, wherein the connecting columns are arranged at the corners of the structural main body flat plate and are used as interfaces and load-bearing components for stacking and connecting with other satellite structures; the structural main body flat plate comprises a plurality of stiffened plates, cross beams and longitudinal beams; the stiffened plates and cross beams are integrally extruded, the cross beams are obtained by removing excess parts from the extruded structure, and the stiffened plates are spliced ​​in sequence to form a plate-like structure; the longitudinal beams are connected to the plate-like structure by splicing.

[0006] The connecting column includes a connecting column body, a lower column and an upper column. The lower column and the upper column are respectively arranged at the upper and lower ends of the connecting column body for adjusting the height of the connecting column. A conical hole is arranged on the lower column, and the lower column is connected to the lower carrier or cone through the conical hole. A conical cone is arranged on the upper column to connect with the upper conical hole.

[0007] It also includes a first lap plate, a first reinforcement plate, a second lap plate and a second reinforcement plate, wherein the lower column and the upper column are stepped cylinders, the lower column includes a lower column large column section and a lower column small column section, and the upper column includes an upper column large column section and an upper column small column section;

[0008] The large column section of the lower column and the large column section of the upper column are consistent with the outer diameter of the connecting column body, the small column section of the lower column passes through the through holes on the second lap plate and the second reinforcing plate, the small column section of the upper column passes through the through holes on the first lap plate and the first reinforcing plate, and the large column section of the lower column and the large column section of the upper column respectively press the lap plate and the reinforcing plate to tighten the connection.

[0009] The connecting column body includes a first connecting arm and a second connecting arm, and the connecting column body is connected to the structural main plate through the first connecting arm and the second connecting arm. The first connecting arm and the second connecting arm are overlapped and fixed with the cross beams and longitudinal beams of the structural main plate through the first lap plate, the first reinforcement plate, the second lap plate and the second reinforcement plate.

[0010] The method for preparing the continuous column body is to obtain a rod material by extrusion molding, and the rod material is cut into sections to obtain the continuous column body.

[0011] When the load connection point is located at the main structural plate and the bearing capacity of the main structural plate is insufficient, a cross-sectional bridging bar is also included. The cross-sectional bridging bar is embedded between two adjacent cross beams and is fixedly connected to the stiffened plate and the longitudinal beam.

[0012] When the load connection point is located at the cross beam or the longitudinal beam, and the load-bearing capacity of the cross beam or the longitudinal beam is insufficient, a support column is also included, and the support column is arranged between the cross beam or the longitudinal beam and the stiffened plate.

[0013] The structural main body flat plate stiffening plate is obtained by cutting the extruded blank obtained by extrusion molding, and the stiffening plates are connected by welding, riveting, screwing or gluing.

[0014] The initial cross-section of the structural main body flat plate reinforced plate is a double-layer hollow structure. The excess part is used as process support and is removed after extrusion molding. The cutting direction of the process support is perpendicular to the flat plate.

[0015] The plurality of stiffened plates and cross beams are extruded and formed by the same die, and then the redundant parts are removed according to different cross beam shape requirements to obtain the cross beams, and the distance between the cross beams of adjacent stiffened plates remains fixed.

[0016] When the precision of the extruded blanks of the main structural plate and the connecting column body is insufficient, the process allowance is increased by machining or transition pieces are added; lap plates are added to the splicing positions of the crossbeams and longitudinal beams, and the connection areas are connected by screws or rivets.

[0017] The longitudinal beam is formed by extrusion or sheet metal bending process, and assembled by screwing or riveting.

[0018] The stiffened plate is provided with a plurality of T-shaped transverse ribs, and the T-shaped transverse ribs are integrally extruded with the stiffened plate, and the T-shaped transverse ribs are obtained by removing redundant parts of the extruded structure.

[0019] Compared with the prior art, the present invention has at least the following beneficial effects:

[0020] (1) The frame flat-panel satellite structure of the present invention adopts a highly efficient extrusion approach molding method, which minimizes the machining workload; the flat-panel frame adopts a unitized design, which greatly reduces the demand for extrusion molding dies;

[0021] (2) The embodiments of the present invention preferably adopt modular and standardized designs to minimize the workload of parts production and assembly; through the combination of modules, the adaptation requirements of various satellite configurations can be achieved;

[0022] (3) The embodiments of the present invention preferably standardize payload connectors with fewer specifications and stronger adaptability, which is beneficial to improving the adaptability of satellite structures to the rapid iteration of payload equipment connection forms. BRIEF DESCRIPTION OF THE DRAWINGS

[0023] Figure 1 This is a schematic diagram of the structure of the frame flat-panel satellite of the present invention;

[0024] Figure 2 It is a schematic diagram of the assembly of the extruded parts of the frame flat-panel satellite structure of the present invention;

[0025] Figure 3 It is a cross-sectional view of the initial extrusion of the frame flat-panel satellite structure of the present invention;

[0026] Figure 4 This is a cross-sectional view of the flat panel after the process support of the frame flat panel satellite structure of the present invention is removed;

[0027] Figure 5 It is a schematic diagram of the flat panel after the process support of the frame flat panel satellite structure of the present invention is removed;

[0028] Figure 6 This is a cross-sectional view of the main body flat panel of the frame flat panel satellite structure of the present invention;

[0029] Figure 7 This is a schematic diagram of all non-extruded parts of the frame flat-panel satellite structure of the present invention;

[0030] Figure 8 It is a schematic diagram of the configuration of the longitudinal beam after blanking and bending forming of the present invention;

[0031] Fig. 9 It is a schematic diagram of the inlaying, splicing and overlapping of the longitudinal beam in the flat plate section of the present invention;

[0032] Fig.10 This is a schematic diagram of the connection between the split columns and the frame of the present invention;

[0033] Fig.11 It is a schematic diagram of the configuration of the connected and divided column body of the present invention;

[0034] Fig.12A schematic diagram of a common connection and a reinforced connection method is provided for the flat panel of the present invention;

[0035] Fig.13 It is a schematic diagram of the reinforced connection method of the cross beam and the main beam of the present invention. DETAILED DESCRIPTION

[0036] The present invention is further described in detail below with reference to the accompanying drawings and specific embodiments:

[0037] like Figure 1 As shown, the frame flat-panel satellite structure includes four cylindrical connecting columns 1, which are used as interfaces and bearing components to be stacked and connected with connecting columns of other stacked satellite structures carried or launched together; the connecting columns include a connecting column body 11, a lower column 12 and an upper column 13; different heights of the connecting columns 1 are obtained by combining the lower column 12 and the upper column 13 of different heights, so as to meet the adjustment of the height between satellite layers and the adaptation requirements of the stacking state such as a layer of double satellites or a layer of single satellite; the connecting column body 11 is obtained by cutting and extruding rods with the same molding die; as shown Fig.10 As shown, the lower column 12 and the upper column 13 are stepped cylinders, the large column section 121 of the lower column and the large column section 131 of the upper column are consistent with the outer diameter of the connecting column body 11, the small column section 122 of the lower column and the small column section 132 of the upper column are provided with external threads, which are connected to the internal threads on the connecting column body 11 through the external threads; the external thread step of the small column section 122 of the lower column is sleeved with the through holes on the second lap plate 8 and the second reinforcing plate 9, and the external thread step of the small column section 132 of the upper column is sleeved with the through holes on the first lap plate 6 and the first reinforcing plate 7, the large column section 121 of the lower column and the large column section 131 of the upper column press the lap plate and the reinforcing plate respectively, and ensure that the lap plate and the reinforcing plate do not fall out after tightening, and transmit and bear the load on the lap plate surface through pressing and sleeve connection. The lower column 12 is provided with a conical hole, through which the lower column 12 is connected to the carrier or the star cone below, and the upper column 13 is provided with a conical cone 133 connected to the star cone hole above.

[0038] like Fig.11 As shown, in the flat-panel satellite structure, the connecting column body 11 is connected to the structural main plate 2 through the first connecting arm 111 and the second connecting arm 112. The first connecting arm 111 and the second connecting arm 112 are wave-reinforced double-layer structure connecting arms. The inner orthogonal walls of the first connecting arm 111 and the second connecting arm 112 are respectively fitted and connected with the flat-panel frame cross beam and the web of the longitudinal beam. The connecting column body 11 is overlapped with the flat-panel frame cross beam and the longitudinal beam at the open end surfaces of the first connecting arm 111 and the second connecting arm 112 through the first lap plate 6, the second lap plate 8, the first reinforcement plate 7 and the second reinforcement plate 9. The overlapping fitting surface is fixed with screws, and it is allowed to be strengthened by gluing; the position of the connecting screws corresponds to the internal wave reinforcement nodes of the first connecting arm 111 and the second connecting arm 112.

[0039] like Figure 2As shown, the main structural plate 2 includes 5 reinforced plates (plate 1 21, plate 2 22, plate 3 23, plate 4 24, plate 5 25) formed by extrusion of aluminum alloy, and a plurality of reinforced T-shaped cross-section ribs (front cross rib 211, plate 1 cross rib 212, plate 1 cross rib 3 213, plate 2 cross rib 1 221, plate 2 cross rib 2 222, plate 2 cross rib 3 223, middle cross front splicing beam 231, plate 3 cross rib 232, middle cross rear splicing beam 241, plate 4 cross rib Two 242, five transverse ribs 1 251 of the flat plate, five transverse ribs 2 252 of the flat plate, and 6 0° direction frame C-section cross beams (front cross beam 214, middle cross front splicing beam 233, middle cross rear splicing beam 243, rear cross beam 253); 5 stiffened plates are welded by front weld 201, middle weld 202, and rear weld 203, and are connected back to back by the webs of middle cross front splicing beam 231, middle cross rear splicing beam 241, and front cross beam 211, finally forming a whole star flat plate with self-contained 0° direction cross beams and cross beams;

[0040] like Figure 7 As shown, the flat-panel satellite structure comprises a C-shaped cross-section longitudinal beam combination structure formed by sheet metal in a perpendicular or other direction to the cross beam, including a left outer front upper longitudinal beam 301, a left outer front lower longitudinal beam 302, a right outer front upper longitudinal beam 303, a right outer front lower longitudinal beam 304, a left inner front upper longitudinal beam 305, a left inner front lower longitudinal beam 306, a right inner front upper longitudinal beam 307, a right inner front lower longitudinal beam 308, a left outer rear upper longitudinal beam 309, a left outer rear lower longitudinal beam 310, a right outer rear upper longitudinal beam 311, a right outer rear lower longitudinal beam 312, a left inner rear upper longitudinal beam 313, a left inner rear lower longitudinal beam 314, a right inner rear upper longitudinal beam 315 and a right inner rear lower longitudinal beam 316; the C-shaped cross-section longitudinal beam combination structure is a standard shape to ensure that the longitudinal beams can be inlaid, spliced ​​and assembled in the main flat panel 2; the longitudinal beams use thin plates for easy laser cutting and are bent into a box shape through sheet metal; as shown Fig. 9 As shown, the joints of the cross beams and longitudinal beams are overlapped by the third overlap plate 4 and the fourth overlap plate 5; the connection area is connected by screws or rivets, and it is allowed to be strengthened by adhesive means.

[0041] In order to improve the adaptability of structural modularization, the four sides of the main structural plate 2 are allowed to be connected to a maximum of four side cabin structures. The main structural plate 2 and the side cabin structure are connected back to back with the side cabin structure web through the C-section side beam. The beams in other directions are aligned in the same line, and the beam flanges are overlapped with lap plates.

[0042] Due to the width limitation of the extruded section, the entire star extruded flat plate is spliced ​​together by several extruded flat plate units. In order to reduce the mold cost, all flat plate unit sections (flat plate 1 21, flat plate 22, flat plate 3 23, flat plate 4 24, flat plate 5 25) can be obtained by cutting from the same extruded section; the sections of all the connected column bodies 11 are completely consistent and can be formed using the same extrusion mold to reduce the mold cost.

[0043] C-shaped (front crossbeam 214, rear crossbeam 253), I-shaped crossbeam (obtained by back-to-back splicing of the middle cross front spliced ​​beam 233 and the middle cross rear spliced ​​beam 243); the flat plate units can all be formed by using the same forming mold to obtain the extruded blank and then cutting different parts; all flat plate splicing includes but is not limited to welding (welds include front weld 201, middle weld 202, rear weld 203, etc.), riveting, screwing, gluing, etc.

[0044] The flat-plate satellite structure allows for the assembly accuracy to be improved by increasing the process allowance for machining or adding transition pieces when the precision of the extruded flat plate and the extruded blanks of the connected column body is not sufficient for direct assembly. The extruded flat plate can also be realized by a pure sheet metal bending process, where the extruded flat plate is disassembled into beams, flat plates, and beams, which are independently formed as standardized sheet metal bending units, and then assembled by screwing or riveting. The configuration adopts a box-shaped structure consistent with the longitudinal beam.

[0045] like Fig.12 As shown, when the load connection point is located at the flat plate, when the load is small, the plate through-hole is used for threaded connection using a support nut; when the load is large and the plate cannot provide sufficient bearing capacity, a C-shaped cross-section bridge bar 245 is provided at the corresponding position of the connection point and is embedded between two adjacent beams (such as 241 and 242) for reinforcement, and the bridge bar 245 and the 0° beam are perpendicular to each other; the bridge bar 245 is connected to the flat plate and the 0° beam by screws or rivets; the bridge bar 245 is standardized in design in coordination with the beam height and spacing to reduce connection specifications and costs; the bridge bar 245 is made of sheet metal or machined; the bridge bar is allowed to provide bidirectional machined threads or through holes at the connection point to meet different connection needs.

[0046] like Fig.13 As shown, when the load connection point is located at the transverse and longitudinal beams, triangular frames or transverse beam flanges, when the load is large and the flanges cannot provide sufficient bearing capacity, a support column 224 is embedded between the flanges and the flat plate at the corresponding position of the connection point. The support column 224 is set between the transverse beam or longitudinal beam and the stiffened plate to strengthen the bearing capacity of the transverse beam or longitudinal beam. The support column 224 is connected to the beam flange and the flat plate with screws or rivets; the support column 224 is standardized in coordination with the spacing between the flanges and the flat plate to reduce the connection specifications and costs.

[0047] like Figure 3-6 As shown, in order to improve the rigidity of the extruded flat plate cross-section, reduce process deformation, and ensure extrusion processability, the initial extrusion cross-section is set to a double-layer hollow structure, and the additional structure is used as a process support, which is removed after extrusion molding; the cutting direction of the process support is perpendicular to the flat plate, in order to simplify processing work and provide convenience for automated laser cutting.

[0048] The C-shaped cross-section longitudinal beam assembly structure can be assembled with the structural main body plate 2 to finally form the satellite structure main body frame; Figure 8 As shown, the longitudinal beam uses a thin plate to facilitate laser cutting, and is bent into a box shape through sheet metal; the joints of the cross beam and the longitudinal beam are overlapped with lap plates; the connection area is connected with screws or rivets, and it is allowed to be strengthened by gluing.

[0049] The multiple stiffened plates and cross beams are extruded by the same die, and then the excess parts are removed according to different cross beam shape requirements to obtain the cross beams. The cross beam spacing between adjacent stiffened plates is fixed, and the longitudinal beams are vertically arranged between adjacent cross beams, so the length of the longitudinal beams is also fixed, which is conducive to the standardization of the longitudinal beams and bridging strips 245.

[0050] The areas where the lap plate strength is insufficient are reinforced by using double-layer stacked reinforcement plates, and both the lap plate and the reinforcement plate are thin plates of equal wall thickness.

[0051] The above description is only the best specific implementation mode of the present invention, but the protection scope of the present invention is not limited thereto. Any changes or substitutions that can be easily thought of by any technician familiar with the technical field within the technical scope disclosed by the present invention should be covered within the protection scope of the present invention.

[0052] The contents not described in detail in the specification of the present invention belong to the common knowledge of the professionals in this field.

Claims

1. A frame flat panel satellite structure based on extrusion and sheet metal forming, characterized in that: The invention comprises a connecting column (1) and a structural main body plate (2); the connecting column (1) is arranged at the corner of the structural main body plate (2) and is used as an interface and a load-bearing component to be stacked and connected with other satellite structures; the structural main body plate (2) comprises a plurality of stiffening plates, cross beams and longitudinal beams; the stiffening plates and cross beams are integrally extruded, the cross beams are obtained by removing redundant parts of the extruded structure, the stiffening plates are spliced ​​in sequence to form a plate-like structure; the longitudinal beams are connected to the plate-like structure by splicing.

2. A frame flat panel satellite structure based on extrusion and sheet metal forming according to claim 1, characterized in that: The connecting column (1) comprises a connecting column body (11), a lower column (12) and an upper column (13), wherein the lower column (12) and the upper column (13) are respectively arranged at the upper and lower ends of the connecting column body (11) and are used to adjust the height of the connecting column (1); a conical hole is arranged on the lower column (12), and the lower column (12) is connected to a carrier or a frustum below through the conical hole; and a frustum (133) is arranged on the upper column (13) and connected to the upper conical hole.

3. A frame flat-panel satellite structure based on extrusion and sheet metal forming according to claim 2, characterized in that: It also includes a first lap plate (6), a first reinforcement plate (7), a second lap plate (8) and a second reinforcement plate (9); the lower column (12) and the upper column (13) are stepped columns; the lower column (12) includes a lower column large column section (121) and a lower column small column section (122); the upper column (13) includes an upper column large column section (131) and an upper column small column section (132); The large column section (121) of the lower column and the large column section (131) of the upper column are consistent with the outer diameter of the connecting column body (11); the small column section (122) of the lower column passes through the through holes on the second lap plate (8) and the second reinforcing plate (9); the small column section (132) of the upper column passes through the through holes on the first lap plate (6) and the first reinforcing plate (7); the large column section (121) of the lower column and the large column section (131) of the upper column respectively press the lap plate and the reinforcing plate to be fastened together.

4. A frame flat panel satellite structure based on extrusion and sheet metal forming according to claim 3, characterized in that: The connecting column body (11) comprises a first connecting arm (111) and a second connecting arm (112); the connecting column body (11) is connected to the structural main plate (2) via the first connecting arm (111) and the second connecting arm (112); the first connecting arm (111) and the second connecting arm (112) are overlapped and fixed to the cross beam and the longitudinal beam of the structural main plate (2) via a first overlap plate (6), a first reinforcement plate (7), a second overlap plate (8) and a second reinforcement plate (9).

5. A frame flat-panel satellite structure based on extrusion and sheet metal forming according to claim 2, characterized in that: The preparation method of the continuous column body (11) is to obtain a rod material by extrusion molding, and the rod material is cut into sections to obtain the continuous column body (11).

6. A frame flat panel satellite structure based on extrusion and sheet metal forming according to claim 1, characterized in that: When the load connection point is located at the structural main body plate (2) and the bearing capacity of the structural main body plate (2) is insufficient, a cross-sectional bridging bar (245) is also included. The cross-sectional bridging bar (245) is embedded between two adjacent cross beams and is fixedly connected to the stiffened plate and the longitudinal beam.

7. A frame flat panel satellite structure based on extrusion and sheet metal forming according to claim 1, characterized in that: When the load connection point is located at the crossbeam or the longitudinal beam, and the crossbeam or the longitudinal beam has insufficient bearing capacity, a support column (224) is also included, and the support column (224) is arranged between the crossbeam or the longitudinal beam and the stiffened plate.

8. The frame flat-panel satellite structure based on extrusion and sheet metal forming according to claim 1, characterized in that: The stiffened plates of the structural main body flat plate (2) are obtained by cutting after obtaining an extruded blank through extrusion molding, and the stiffened plates are connected by welding, riveting, screwing or gluing.

9. The frame flat-panel satellite structure based on extrusion and sheet metal forming according to claim 1, characterized in that: The initial cross-section of the structural main plate (2) reinforced plate after extrusion is a double-layer hollow structure, and the excess part is used as a process support and is removed after extrusion molding. The cutting direction of the process support is perpendicular to the plate.

10. A frame flat panel satellite structure based on extrusion and sheet metal forming according to claim 9, characterized in that: The plurality of stiffened plates and cross beams are extruded and formed by the same die, and then the redundant parts are removed according to different cross beam shape requirements to obtain the cross beams, and the cross beam spacing between adjacent stiffened plates remains fixed.

11. The frame flat-panel satellite structure based on extrusion and sheet metal forming according to claim 5, characterized in that: When the extruded blanks of the structural main body plate (2) and the connecting column body (11) are not accurate enough, machining is performed to increase the process margin or transition pieces are added; overlapping plates are added to the splicing positions of the cross beams and longitudinal beams, and the connection areas are connected by screws or rivets.

12. A frame flat panel satellite structure based on extrusion and sheet metal forming according to claim 1, characterized in that: The longitudinal beam is formed by extrusion or sheet metal bending process, and assembled by screwing or riveting.

13. The frame flat-panel satellite structure based on extrusion and sheet metal forming according to claim 1, characterized in that: The stiffened plate is provided with a plurality of T-shaped transverse ribs, and the T-shaped transverse ribs are integrally extruded with the stiffened plate, and the T-shaped transverse ribs are obtained by removing redundant parts of the extruded structure.

Images