In-orbit continuous forming device and method for composite material truss structure

Abstract

The application discloses a kind of composite truss structure's on-orbit continuous forming device and method thereof, device includes: frame support structure, longitudinal beam feeding module, crossbeam feeding module, cable feeding module and connecting function module.Longitudinal beam composite material strip supplied by longitudinal beam feeding module, crossbeam composite material strip supplied by crossbeam feeding module, cable composite material are connected to be supplied by cable feeding module, to form composite truss structure.Each composite material is respectively transported to the work area of frame support structure by longitudinal beam feeding module, crossbeam feeding module and cable feeding module, and the efficient connection of each composite material is realized by connecting function module and node forming, finally realizes the on-orbit continuous forming of composite truss structure, significantly improves the overall stiffness, carrying capacity and manufacturing efficiency of large space structure, breaks through the size limit of space structure of ground manufacturing-on-orbit deployment, meets the actual demand of on-orbit assembly and deployment.

Description

Technical Field

[0001] This invention relates to the field of on-orbit manufacturing technology in aerospace, and more particularly to an on-orbit continuous forming device and method for composite material truss structures. Background Technology

[0002] Under current technological conditions, most spacecraft structures are typically 10 to 100 meters in size, with manufacturing largely done on the ground before being launched into their designated orbit by a launch vehicle. However, for the next generation of large spacecraft, the scale of their structural support systems will expand to the 0.1 to 10 kilometer range. These ultra-large-scale space structures are limited by the size of the launch vehicle fairing, making a single launch of such massive space structures difficult and rendering the existing ground-based manufacturing-on-orbit deployment model unsuitable. Even if large structures are disassembled and launched in batches on the ground for on-orbit assembly, limitations in assembly precision still exist, affecting system lifespan and stability, and resulting in extremely high launch costs.

[0003] Therefore, existing technologies still need improvement and development. Summary of the Invention

[0004] The technical problem to be solved by the present invention is to provide an on-orbit continuous forming device and method for composite material truss structures, which addresses the above-mentioned deficiencies of the prior art and aims to solve the problem of size limitation of aerospace structures manufactured on the ground and deployed in orbit in the prior art.

[0005] The technical solution adopted by this invention to solve the technical problem is as follows:

[0006] An on-orbit continuous forming apparatus for composite material truss structures, comprising:

[0007] A frame support structure, wherein the frame support structure is prismatic in shape;

[0008] Multiple longitudinal beam feeding modules are located at the rear end of the side edges in the frame support structure;

[0009] Multiple beam feeding modules are located at corresponding positions on the side of the frame support structure;

[0010] Multiple cable-stayed bridge feeding modules are located at the front end of the side edge and the corresponding position of the bottom edge in the frame support structure, respectively;

[0011] Multiple connection functional modules are located at the corresponding positions of the vertices in the frame support structure;

[0012] The connection module is configured to connect the longitudinal beam composite material strips supplied by the longitudinal beam supply module, the crossbeam composite material strips supplied by the crossbeam supply module, and the cable-stayed composite material supplied by the cable-stayed cable supply module to form a composite material truss structure.

[0013] The on-orbit continuous forming device for the composite material truss structure, wherein the longitudinal beam composite material strip includes an upper composite material strip and a lower composite material strip; the longitudinal beam feeding module includes:

[0014] The folding extension arm and the connecting device are both located at the rear end of the side edge in the frame support structure;

[0015] Both the upper composite material strip roll and the lower composite material strip roll are disposed on the folding extension arm;

[0016] The upper composite material strip is flattened and wound onto the upper composite material strip roll;

[0017] The lower composite material strip is flattened and wound onto the lower composite material strip roll;

[0018] The upper composite material strip is V-shaped in a stress-free state, and the lower composite material strip is W-shaped in a stress-free state. The edges of the upper composite material strip and the edges of the lower composite material strip are connected to form the longitudinal beams of the composite material truss structure.

[0019] The connecting device is configured to connect the end of the remaining longitudinal beam composite strip and the front end of the newly added longitudinal beam composite strip.

[0020] The on-orbit continuous forming device for the composite material truss structure, wherein the connecting device includes:

[0021] A supporting base block is provided in the frame support structure;

[0022] The first and second flattening rollers are respectively disposed on both sides of the support base block;

[0023] A connecting bracket is provided on the frame support structure;

[0024] A connecting unit is disposed on the connecting bracket;

[0025] The connecting unit is located above the supporting base block.

[0026] The on-orbit continuous forming device for the composite material truss structure, wherein the beam feeding module includes:

[0027] A drawer-type storage bin is located on the side of the frame support structure and is configured to hold the composite material strip of the crossbeam;

[0028] A drive and push device is installed in the drawer-type storage box;

[0029] A beam feeding pusher is located inside the drawer-type storage box and connected to the drive pushing device;

[0030] The beam feeding pusher, under the drive and push device, pushes the beam composite material strip inside the drawer-type storage box.

[0031] The on-orbit continuous forming device for the composite material truss structure, wherein the crossbeam composite material strip includes: a first composite material strip and a second composite material strip;

[0032] Both the first composite material strip and the second composite material strip are Ω-shaped;

[0033] The first composite material strip and the second composite material strip protrude to both sides respectively, and the edges of the first composite material strip and the edges of the second composite material strip are connected.

[0034] The on-orbit continuous forming device for the composite material truss structure, wherein the cable feeding module includes:

[0035] The cable coil, the material switching device, and the constant tension control mechanism are sequentially arranged at the front end of the side edge of the frame support structure;

[0036] A reciprocating arrangement mechanism is installed at the corresponding position of the bottom edge of the frame support structure;

[0037] The cable-stayed composite material is wound around the cable-stayed material roll;

[0038] The switching device is configured to connect the remaining cable-stayed composite material with the newly added cable-stayed composite material;

[0039] The constant tension control mechanism is configured to adjust the output tension of the cable-stayed composite material;

[0040] The reciprocating arrangement mechanism is configured to move along the bottom edge direction of the frame support structure to adjust the position of the cable-stayed composite material.

[0041] The on-orbit continuous forming device for the composite material truss structure, wherein the reciprocating arrangement mechanism includes:

[0042] Both the lead screw and the guide rod are located on the bottom edge of the frame support structure;

[0043] The mounting head is threadedly connected to the lead screw and slides relative to the guide rod;

[0044] A commutator is disposed on the frame support structure and connected to the lead screw;

[0045] A variable-height diagonal brace is provided in the frame support structure and configured to adjust the height of the arrangement head;

[0046] The arrangement head is configured to connect the cable-stayed composite material.

[0047] The on-orbit continuous forming device for the composite material truss structure, wherein the connecting functional module includes:

[0048] A position control device is installed at the position corresponding to the vertex in the frame support structure;

[0049] A connection unit is disposed in the position control device;

[0050] The position control device is configured to adjust the position of the connecting unit;

[0051] The connecting unit is configured to connect the longitudinal beam composite strip, the transverse beam composite strip, and the cable composite material.

[0052] The on-orbit continuous forming device for the composite material truss structure, wherein the frame support structure includes:

[0053] A central load-bearing cylinder, wherein the central load-bearing cylinder is prismatic in shape;

[0054] Several supporting uprights are fitted onto the outside of the central load-bearing cylinder;

[0055] Several mounting plates are disposed on the supporting upright plate.

[0056] A forming method for an on-orbit continuous forming apparatus for composite material truss structures as described in any one of the above claims, comprising the steps of:

[0057] The control connection function module connects the longitudinal beam composite material strip, the transverse beam composite material strip, and the cable composite material;

[0058] The control module supplies cable-stayed composite material to the cable-stayed cable, the control module supplies longitudinal beam composite material strip to the longitudinal beam, and the control module connects the longitudinal beam composite material strip.

[0059] After the longitudinal beam composite material strip is supplied to a preset length, the longitudinal beam feeding module stops supplying the longitudinal beam composite material strip, and the crossbeam feeding module supplies the crossbeam composite material strip. The cable feeding module moves the cable composite material, and the connection function module connects the longitudinal beam composite material strip, the crossbeam composite material strip, and the cable composite material.

[0060] Continue executing the steps of controlling the cable-stayed cable supply module to supply cable composite material, controlling the longitudinal beam supply module to supply longitudinal beam composite material strip, and controlling the connection function module to connect the longitudinal beam composite material strip, until the longitudinal beam composite material strip is supplied to the target length, thus obtaining a composite material truss structure.

[0061] Beneficial effects: Various composite materials are transported to the working area of ​​the frame support structure by the longitudinal beam supply module, the cross beam supply module and the cable supply module according to a predetermined rhythm. Under the spatial reference of the frame support structure, they are precisely positioned by automated processes. The efficient connection and node forming of each composite material are achieved through the connection function module, and finally the on-orbit continuous forming of composite material truss structure is realized. This significantly improves the overall stiffness, load-bearing capacity and manufacturing efficiency of large space structure, breaks through the size limitations of aerospace structure manufactured on the ground and deployed on the orbit, and meets the actual needs of on-orbit assembly and deployment. Attached Figure Description

[0062] Figure 1 This is a first structural schematic diagram of the on-orbit continuous forming device for composite material truss structure in an embodiment of the present invention.

[0063] Figure 2 This is a schematic diagram of the frame support structure in an embodiment of the present invention.

[0064] Figure 3 This is a structural schematic diagram of the longitudinal beam feeding module in an embodiment of the present invention.

[0065] Figure 4 This is a schematic diagram of the connecting device in an embodiment of the present invention.

[0066] Figure 5 This is a schematic diagram of the longitudinal beam composite material strip in an embodiment of the present invention.

[0067] Figure 6 This is a structural schematic diagram of the beam feeding module in an embodiment of the present invention.

[0068] Figure 7 This is a schematic diagram of the structure of the composite material strip for the beam in an embodiment of the present invention.

[0069] Figure 8 This is a second structural schematic diagram of the on-orbit continuous forming device for composite material truss structure in an embodiment of the present invention.

[0070] Figure 9 This is a schematic diagram of the constant tension control mechanism in an embodiment of the present invention.

[0071] Figure 10 This is a schematic diagram of the reciprocating arrangement mechanism in an embodiment of the present invention.

[0072] Explanation of reference numerals in the attached figures:

[0073] 10. Frame support structure; 11. Central load-bearing cylinder; 12. Supporting vertical plate; 13. Mounting plate;

[0074] 20. Longitudinal beam feeding module; 201. Longitudinal beam composite material strip; 202. Upper composite material strip; 203. Lower composite material strip; 21. Folding extension arm; 22. Connecting device; 221. Support base block; 222. First flattening roller; 223. Second flattening roller; 224. Connecting bracket; 225. Connecting unit; 23. Upper composite material strip roll; 24. Lower composite material strip roll;

[0075] 30. Crossbeam feeding module; 301. Crossbeam composite material strip; 302. First composite material strip; 303. Second composite material strip; 31. Drawer-type storage box; 32. Drive and push device; 33. Crossbeam feeding pusher block; 34. Fixed support assembly;

[0076] 40. Cable feeding module; 401. Cable composite material; 41. Cable roll; 42. Material switching device; 43. Constant tension control mechanism; 431. Fixed winding wheel; 432. Fixed pulley; 433. Constant torque coil spring; 434. Movable pulley; 435. Slide rail; 436. Winding guide wheel; 44. Reciprocating arrangement mechanism; 441. Lead screw; 442. Guide rod; 443. Arrangement head; 444. Reversing device; 445. Variable height diagonal brace;

[0077] 50. Connection function module; 51. Connection unit. Detailed Implementation

[0078] To make the objectives, technical solutions, and advantages of this invention clearer and more explicit, the invention will be further described in detail below with reference to the accompanying drawings and embodiments. It should be understood that the specific embodiments described herein are merely illustrative of the invention and are not intended to limit the invention.

[0079] Please also refer to Figures 1-10 The present invention provides some embodiments of an on-orbit continuous forming device for composite material truss structures.

[0080] like Figure 1 As shown, the on-orbit continuous forming apparatus for composite material truss structures of the present invention includes:

[0081] The frame support structure 10 is prism-shaped.

[0082] Multiple longitudinal beam feeding modules 20 are located at the rear end of the side edges in the frame support structure 10.

[0083] Multiple beam feeding modules 30 are respectively located at corresponding positions on the side of the frame support structure 10;

[0084] Multiple cable-stayed bridge feeding modules 40 are respectively located at the front end of the side edge and the corresponding position of the bottom edge in the frame support structure 10;

[0085] Multiple connection functional modules 50 are respectively located at the corresponding positions of the vertices in the frame support structure 10;

[0086] The connection module 50 is configured to connect the longitudinal beam composite material strip 201 supplied by the longitudinal beam supply module 20, the crossbeam composite material strip 301 supplied by the crossbeam supply module 30, and the cable-stayed composite material 401 supplied by the cable-stayed supply module 40 to form a composite material truss structure.

[0087] Specifically, the frame support structure 10 serves as the overall foundation platform of the device, providing precise spatial positioning references and structural support for each material supply module and connecting functional module 50, ensuring good rigidity, strength, and stability when the modules work together. The longitudinal beam material supply module 20 stores, transports, and positions the longitudinal beam composite material strip 201, ensuring that the longitudinal beam composite material strip 201 is supplied to a fixed length and in a directional manner within the device, providing a material basis for the subsequent forming of the longitudinal beams of the composite truss structure. The crossbeam material supply module 30 provides the crossbeam composite material strip 301, capable of outputting the crossbeam composite material strip 301 according to the truss structure design requirements and automatically positioning it at the predetermined assembly position. The cable-stayed bridge material supply module stores and transports the inclined cable composite material, releasing and positioning it as needed, realizing the inclined structural arrangement at the nodes of the composite truss structure, and enhancing the overall stability and load-bearing capacity of the composite truss structure. The connection module 50 enables efficient and automatic connection and node forming of longitudinal beam composite strip 201, transverse beam composite strip 301 and cable composite 401, supporting multiple connection methods such as riveting, welding and gluing, to meet the diverse assembly needs of space truss structures.

[0088] The frame support structure 10 provides precise positioning and a reliable load-bearing foundation for each material supply module and connecting functional module 50. Various composite materials are transported to the working area of ​​the frame support structure 10 by the longitudinal beam supply module 20, the transverse beam supply module 30, and the cable supply module 40 according to a predetermined rhythm. Under the spatial reference of the frame support structure 10, they are precisely positioned by automated processes, and the connecting functional module 50 realizes the efficient connection and node forming of each composite material. Ultimately, the on-orbit continuous forming of the composite truss structure is achieved, which significantly improves the overall stiffness, load-bearing capacity, and manufacturing efficiency of large space structures. It breaks through the size limitations of aerospace structures manufactured on the ground and deployed in orbit, and meets the actual needs of on-orbit assembly and deployment.

[0089] If the frame support structure 10 is prismatic, then the composite truss structure will also be prismatic, and the prism can be triangular, square, or pentagonal, etc. The prism has lateral edges and a base edge, forming side surfaces and a bottom surface. For example, a triangular prism has three lateral edges and three side surfaces, and a triangular prism has six base edges and two bottom surfaces. The composite truss structure includes longitudinal beams, transverse beams, and stay cables. The longitudinal beams are located at the lateral edges of the prism, and the number of longitudinal beams is the same as the number of lateral edges. The transverse beams are located at the base edges of the prism and at positions parallel to the base edges and connected to the lateral edges; the number of transverse beams is greater than the number of base edges. The longitudinal beams and transverse beams are interconnected, forming multiple rectangular frames on the sides of the prism. The stay cables are located on the sides of the prism and distributed along the diagonals of the rectangular frames. Each prism has two stay cables on its side, and the two stay cables are staggered.

[0090] The longitudinal beam composite strip 201, the transverse beam composite strip 301, and the stay cable composite strip 401 are made of lightweight, high-strength, thermally stable, corrosion-resistant, and radiation-resistant composite materials. By constructing the composite truss structure through continuous on-orbit forming, lightweight and high-strength properties are achieved, significantly reducing launch load. The composite strips possess excellent thermal stability, maintaining structural strength and precision in the alternating high and low temperature environment of space. The materials exhibit excellent corrosion resistance and radiation resistance, adapting to harsh on-orbit conditions such as high-energy particle irradiation, maintaining structural integrity and functional stability. The overall structure of the device is compact and rationally arranged. Combined with an automatic control system, it enables efficient, continuous, and reliable on-orbit forming and connection operations, facilitating engineering deployment and widespread application.

[0091] In a preferred implementation of this invention, such as Figures 1-2 As shown, the frame support structure 10 includes:

[0092] The central load-bearing cylinder 11 is prismatic in shape.

[0093] Several supporting uprights 12 are fitted over the central load-bearing cylinder 11;

[0094] Several mounting plates 13 are disposed on the supporting upright plate 12.

[0095] Specifically, the central load-bearing cylinder 11 is located at the center and is prismatic in shape, identical in shape to the composite material truss structure, which surrounds the central load-bearing cylinder 11. Supporting plates 12 are polygonal rings and are arranged around the central load-bearing cylinder 11. The supporting plates 12 are connected to the central load-bearing cylinder 11 and the mounting plate 13, respectively, to allow the mounting plate 13 to install other modules. The central load-bearing cylinder 11 is the core load-bearing component of the entire device, arranged along the device's axis, and is used to bear and transmit the main loads of each module and during assembly, ensuring the structural rigidity and overall stability of the device during on-orbit operation. The central load-bearing cylinder 11 can be made of high-strength lightweight alloy or composite material to balance weight and load-bearing capacity. The supporting plates 12 are vertically installed at several positions around the central load-bearing cylinder 11, serving as secondary load-bearing and spatial separation components of the overall device structure. On the one hand, the supporting plate 12 is fixedly connected to the central load-bearing cylinder 11 through high-strength fasteners or welding, further enhancing the overall bending and torsional stiffness of the frame. On the other hand, the supporting plate 12 provides spatial reference and structural support for the installation, positioning, and adjustment of each module, which is conducive to improving the convenience of modular integration and subsequent maintenance. The supporting plate 12 can be pre-set with multiple mounting holes, guide rails, or limiting grooves according to specific functional requirements, for the rapid arrangement and fixing of each module (such as material supply, connection, etc.) and accessories such as cables and pipelines, improving the versatility and expandability of the structure. The frame support structure 10, as the basic load-bearing and assembly platform, provides precise installation references and reliable structural support for each material supply module, connection module, etc., ensuring the overall structural accuracy and operational safety of the on-orbit continuous forming device. The above structural design helps to improve the engineering feasibility and operational reliability of on-orbit forming and assembly of large-size spatial truss structures.

[0096] In a preferred implementation of this invention, such as Figure 5 As shown, the longitudinal beam composite material strip 201 includes an upper composite material strip 202 and a lower composite material strip 203.

[0097] Specifically, the longitudinal beam composite material strip 201 is formed by connecting two composite material strips, namely the upper composite material strip 202 and the lower composite material strip 203. The upper composite material strip 202 is located on the outside of the longitudinal beam, and the lower composite material strip 203 is located on the inside of the longitudinal beam.

[0098] In a preferred implementation of this invention, such as Figures 1-3 As shown, the longitudinal beam feeding module 20 includes:

[0099] The folding extension arm 21 and the connecting device 22 are both located at the rear end of the side edge in the frame support structure 10.

[0100] The upper composite material strip roll 23 and the lower composite material strip roll 24 are both disposed on the folding extension arm 21;

[0101] The upper composite material strip 202 is flattened and wound onto the upper composite material strip roll 23; the lower composite material strip 203 is flattened and wound onto the lower composite material strip roll 24; the upper composite material strip 202 is V-shaped in a stress-free state, and the lower composite material strip 203 is W-shaped in a stress-free state, and the edges of the upper composite material strip 202 and the edges of the lower composite material strip 203 are connected to form the longitudinal beams of the composite material truss structure; the connecting device 22 is configured to connect the end of the remaining longitudinal beam composite material strip and the front end of the newly added longitudinal beam composite material strip.

[0102] Specifically, the folding extension arm 21 is mounted on the central load-bearing cylinder 11, and the connecting device 22 is mounted on the central load-bearing cylinder 11 and the supporting upright plate 12. The upper composite material strip roll 23 and the lower composite material strip roll 24 are used to store and output the upper composite material strip 202 and lower composite material strip 203 required for the longitudinal beam structure, respectively. The material rolls are unwound under constant tension through a tensioning and guiding mechanism to ensure that the strips do not slip, loosen, or break during transport. The cross-sectional structure of the longitudinal beam is as follows... Figure 5 As shown, under stress-free conditions, the upper composite material strip 202 and the lower composite material strip 203 are not subjected to compression. The upper composite material strip 202 exhibits a V-shape, while the lower composite material strip 203 exhibits a W-shape. This cross-sectional structural design is beneficial for improving the bending stiffness and overall stability of the longitudinal beam, while also facilitating automated feeding and forming. The upper composite material strip 202 and the lower composite material strip 203 have the same width in the flattened state.

[0103] The folding extension arm 21 is installed at the output end of the feeding module and is used to extend in the working state to provide effective guidance and support for the upper composite material strip 202 and the lower composite material strip 203. The folding extension arm 21 has automatic unfolding and retraction functions. It can be compactly stored during the launch or transportation stage and automatically unfolds after entering the working stage to form a stable guide path, ensuring that the composite material strip is fed into the subsequent forming station with accurate posture and trajectory.

[0104] The connecting device 22 is installed in the strip unwinding path to enable rapid, efficient, and automatic connection of newly added longitudinal beam composite material strip with the remaining longitudinal beam composite material strip when the strip is about to run out. The connecting device 22 aligns the front end of the newly added longitudinal beam composite material strip with the end of the remaining strip and securely connects them through pressing, hot melting, mechanical fastening, or adhesive bonding, ensuring uninterrupted material supply. This significantly improves the operating efficiency and strip utilization rate of the on-orbit continuous forming system, avoiding downtime, waste, and production discontinuity caused by material replacement.

[0105] The longitudinal beam feeding module 20 synchronously controls the unwinding speed of the upper composite material strip roll 23 and the lower composite material strip roll 24. The two rolls of strip are fixedly installed on the folding extension arm 21 and, after being guided by the folding extension arm 21, are precisely fed into the forming station. The connecting device 22 can automatically and smoothly complete the docking and connection of the new and old materials when the composite material strip is changed, providing a continuous and stable material guarantee for subsequent forming, connection and truss structure assembly.

[0106] In a preferred implementation of this invention, such as Figures 3-4 As shown, the connecting device 22 includes:

[0107] A support block 221 is provided on the frame support structure 10;

[0108] The first flattening roller 222 and the second flattening roller 223 are respectively disposed on both sides of the support base block 221;

[0109] Connecting bracket 224 is disposed on the frame support structure 10;

[0110] Connecting unit 225 is disposed on the connecting bracket 224;

[0111] The connecting unit 225 is located above the supporting base block 221.

[0112] Specifically, the support base 221 is mounted on the central load-bearing cylinder 11, and the connecting bracket 224 is mounted on the support upright 12. The connecting bracket 224 serves as a load-bearing and positioning foundation, used to precisely fix and install the connecting unit 225, and provides driving support to achieve efficient connection of new and old strip materials. The connecting unit 225 is used to achieve rapid positioning and connection of the ends of new and old strip materials, and can employ various connection methods such as mechanical fastening, hot melting, and adhesive bonding to ensure the firmness and continuity of the connection. Two flattening rollers (i.e., the first flattening roller 222 and the second flattening roller 223) are positioned on the front and rear sides of the connection area to apply uniform pressure to the new and old strip materials during the connection process, compacting and flattening the connection, improving the connection quality, and preventing localized warping. The support base 221 is located below the connection area, providing stable support and reaction force for the strip material, working in conjunction with the two flattening rollers to ensure the flatness and reliability of the connection process. The connecting device 22 positions the new and old strips in the connecting unit 225 through the connecting bracket 224. Then, it uses two flattening rollers and a support base block 221 to compact the connecting part, so as to achieve efficient and stable connection of the new and old materials, ensure that the material supply process is continuous and uninterrupted, and provide a reliable guarantee for continuous forming operation on the track.

[0113] In a preferred implementation of this invention, such as Figure 1 and Figure 6 As shown, the beam feeding module 30 includes:

[0114] A drawer-type storage box 31 is located on the side of the frame support structure 10 and is configured to load the crossbeam composite material strip 301;

[0115] A drive and push device 32 is provided in the drawer-type storage box 31;

[0116] The beam feeding pusher 33 is located inside the drawer-type storage box 31 and is connected to the driving pusher 32;

[0117] The beam feeding pusher 33, under the drive pushing device 32, pushes the beam composite material strip 301 in the drawer-type storage box 31.

[0118] Specifically, the drawer-type storage box 31 is mounted on the side of the frame support structure 10 via a fixed support assembly 34, specifically on the mounting plate 13. The fixed support assembly 34 provides stable structural support and spatial positioning reference for the storage of the drawer-type storage box 31, ensuring the overall rigidity and accuracy of the beam feeding module 30 during operation. The drive pushing device 32 provides power for the beam feeding process, using actuators such as motors to drive the beam feeding pusher 33, realizing quantitative and timed pushing of the beam, accurately conveying the beam material to the forming and assembly station. The beam feeding pusher 33 is installed at the power output end of the drive pushing device 32, and is used to directly contact and push the beam. The surface of the beam feeding pusher 33 can be provided with anti-slip texture or buffer layer to prevent damage to the surface of the beam composite material strip 301 during the pushing process. The drawer-type storage box 31 is used to store batches of crossbeam composite material strips 301. It features a pull-out and replaceable structural design, facilitating on-orbit material replenishment and maintenance operations. Simultaneously, it ensures that the crossbeam composite material strips 301 are output sequentially, improving automated feeding efficiency. Different cross-sections, lengths, and material specifications of the crossbeam composite material strips 301 can be selected according to the design requirements of the composite truss structure, meeting the diverse needs of continuous forming of spatial structures.

[0119] The beam feeding module 30, through the drive pushing device 32, drives the beam feeding pusher 33 to push the beam composite material strips 301 one by one from the drawer-type storage box 31 and transport them to the designated workstation. During the pushing process, the fixed support component 34 provides structural support and guidance for the entire feeding system, ensuring the precise alignment of the beam composite material strips 301. The above structural design realizes efficient and stable automatic feeding of beam materials, providing a reliable material foundation for subsequent truss structure forming and assembly.

[0120] In a preferred implementation of this invention, such as Figures 6-7 As shown, the crossbeam composite material strip 301 includes: a first composite material strip 302 and a second composite material strip 303; both the first composite material strip 302 and the second composite material strip 303 are Ω-shaped; the first composite material strip 302 and the second composite material strip 303 protrude to both sides respectively, and the edge of the first composite material strip 302 and the edge of the second composite material strip 303 are connected.

[0121] Specifically, the crossbeam composite strip 301 is formed by connecting two composite strips. The first composite strip 302 and the second composite strip 303 are both Ω-shaped, and the first composite strip 302 and the second composite strip 303 protrude toward the two sides of the crossbeam composite strip 301 respectively, so that the crossbeam composite strip 301 is hollow in a stress-free state.

[0122] In a preferred implementation of this invention, such as Figure 8 As shown, the cable-stayed bridge feeding module 40 includes:

[0123] The cable coil 41, the material switching device 42, and the constant tension control mechanism 43 are sequentially arranged at the front end of the side edge of the frame support structure 10.

[0124] A reciprocating arrangement mechanism 44 is disposed at the corresponding position of the bottom edge of the frame support structure 10;

[0125] The cable-stayed composite material 401 is wound around the cable-stayed material roll 41;

[0126] The switching device 42 is configured to connect the remaining cable composite material and the newly added cable composite material; the constant tension control mechanism 43 is configured to adjust the output tension of the cable composite material 401; the reciprocating arrangement mechanism 44 is configured to move along the bottom edge direction of the frame support structure 10 to adjust the position of the cable composite material 401.

[0127] Specifically, the cable reel 41, the switching device 42, and the constant tension control mechanism 43 are mounted on the mounting plate 13, while the reciprocating arrangement mechanism 44 is mounted on the supporting plate 12. The cable reel 41 stores the required length of cable composite material 401 and has a limit protection function to ensure stable performance and sufficient supply of the cable composite material 401 during long-term storage on the rail. The switching device 42 is located on the reel's discharge path and is used to quickly switch and connect new and old cable composite materials when a single reel of cable composite material 401 is exhausted. This device can integrate automatic detection, positioning, and docking mechanisms, supporting seamless replacement of the cable composite material 401 and ensuring the continuity and efficiency of the supply process. The constant tension control mechanism 43 is arranged on the unwinding path of the cable composite material 401 and is used to adjust the output tension of the cable composite material 401 in real time to prevent slippage, slackness, or tensile deformation of the cable composite material 401 during conveying and arrangement. The constant tension control mechanism 43 employs a force-controlled tension wheel, tension sensor, and automatic feedback adjustment system to achieve dynamic closed-loop control, ensuring the forming and assembly accuracy of the stay cables. The reciprocating arrangement mechanism 44 drives the stay cable composite material 401 to be precisely laid and positioned between spatial truss nodes according to a predetermined trajectory, efficiently guiding the stay cable composite material 401 to the target node at a predetermined angle, length, and tension, achieving automated arrangement of multiple stay cable composite materials 401. The stay cable feeding module continuously supplies stay cables through the stay cable roll 41. After passing through the material switching device 42 and the constant tension control mechanism 43, the reciprocating arrangement mechanism 44 precisely lays the stay cable composite material 401 to each designated node, achieving automatic integration and connection of the stay cable composite material 401 with longitudinal beam composite strips 201, transverse beam composite strips 301, and other structures, effectively improving the overall stiffness and stability of the spatial truss structure.

[0128] In a preferred implementation of this invention, such as Figure 9 As shown, the constant tension control mechanism 43 includes: a fixed winding wheel 431, a fixed pulley 432, a constant torque coil spring 433, a movable pulley 434, a slide rail 435, and a winding guide wheel 436; the fixed winding wheel 431, the fixed pulley 432, the constant torque coil spring 433, the slide rail 435, and the winding guide wheel 436 are all disposed on the frame support structure 10; the movable pulley 434 slides relative to the slide rail 435 and is connected to the constant torque coil spring 433.

[0129] Specifically, the fixed winding wheel 431 is used to fix one end of the cable-stayed composite material 401, realizing the orderly winding and unwinding of the material and path control. The fixed pulley 432 is set at a specific position in the feeding path to guide the material to move in a predetermined direction and change the path of force application. The constant torque coil spring 433 is linked to the movable pulley 434 to provide a constant pull force to the material, ensuring that the material is always in a constant tension state during unwinding or conveying, effectively avoiding material slippage, loosening or breakage caused by tension fluctuations. The movable pulley 434 is installed on the slide rail 435 and can move back and forth along the slide rail 435. It automatically adjusts its position according to the change of material length and compensates for tension changes in real time under the drive of the constant torque coil spring 433, maintaining a stable output of constant tension in the system. The slide rail 435 provides guidance and support for the movement of the movable pulley 434, ensuring the straightness and positional accuracy of its movement. The winding guide wheel 436 is positioned at the turning point of the material conveying path to further optimize the material conveying direction, reduce frictional resistance, and improve the overall smoothness and reliability of the constant tension control mechanism 43. The constant tension control mechanism 43 guides the material path through the fixed winding wheel 431, fixed pulley 432, and winding guide wheel 436. After passing the movable pulley 434, the material is continuously provided with constant tension by the constant torque coil spring 433. The movable pulley 434 can move freely on the slide rail 435, automatically adjusting its position according to changes in material length to achieve real-time tension compensation. The coordinated operation of all components effectively ensures constant tension and operational stability of the material during conveying and arrangement.

[0130] In a preferred implementation of this invention, such as Figure 8 and Figure 10 As shown, the reciprocating arrangement mechanism 44 includes:

[0131] Both the lead screw 441 and the guide rod 442 are located on the bottom edge of the frame support structure 10;

[0132] The arrangement head 443 is threadedly connected to the lead screw 441 and slides relative to the guide rod 442;

[0133] Commutator 444 is disposed on the frame support structure 10 and connected to the lead screw 441;

[0134] A variable-height diagonal brace 445 is provided on the frame support structure 10 and configured to adjust the height of the arrangement head 443;

[0135] The arrangement head 443 is configured to connect the cable-stayed composite material 401.

[0136] Specifically, the guide rod 442 provides precise linear guidance for the placement head 443, ensuring the smoothness and positioning accuracy of the placement process. The lead screw 441, driven by a motor, drives the placement head 443 to reciprocate along the guide rod 442, automatically laying the cable-stayed composite material 401 to the target node along a set path. The placement head 443 is the actuator at the cable-stayed composite material 401's outlet end, possessing functions such as clamping, positioning, and guiding, achieving precise placement and fixation of the material. The variable-height brace 445 adjusts the height of the placement head 443 to adapt to different node positions and spatial trajectory requirements, improving placement flexibility. The commutator 444 transmits torque and changes the transmission direction of the lead screw 441, thereby enabling the placement head 443 to reciprocate along the guide rod 442, meeting the requirements of automatic placement. The reciprocating arrangement mechanism 44 drives the arrangement head 443 to reciprocate along the guide rod 442 via the lead screw 441. Combined with the height adjustment of the variable height brace 445 and the automatic reversing of the commutator 444, the efficient and precise automatic arrangement of the cable-stayed composite material 401 is achieved.

[0137] In a preferred implementation of this invention, such as Figure 8 As shown, the connection function module 50 includes:

[0138] A position control device is installed at the position corresponding to the vertex in the frame support structure 10;

[0139] Connection unit 51 is disposed in the position control device;

[0140] The position control device is configured to adjust the position of the connecting unit 51; the connecting unit 51 is configured to connect the longitudinal beam composite material strip 201, the crossbeam composite material strip 301 and the cable-stayed composite material 401.

[0141] Specifically, the position control device and the connection unit 51 are mounted on the mounting plate 13. The connection unit 51 is used to realize the node connection of composite material components such as longitudinal beams, transverse beams, and stay cables. It can be equipped with various connection methods such as riveting, welding, gluing, and bolting according to different connection requirements, adapting to different material types and structural mechanics requirements. The connection unit 51 can integrate functional modules such as automatic feeding, clamping, connection, and loosening to realize the automation and high reliability of the connection process. The position control device is used to precisely adjust and control the spatial position and connection posture of the connection unit 51 to ensure the docking accuracy and connection quality of each component to be connected at the node. The position control device can adopt precision slide table or spatial positioning mechanism, combined with sensors and automatic control system, to realize closed-loop adjustment of the connection operation, adapting to the automatic docking connection requirements of different node positions and multiple types of components. According to the node layout requirements of the forming station, the connection function module 50 moves the connection unit 51 to the target node position through the position control device to realize the precise positioning and automatic connection of each component, completing the efficient and batch assembly of the space truss structure.

[0142] Based on the on-orbit continuous forming apparatus for composite material truss structures described in any of the above embodiments, the present invention also provides a preferred embodiment of the forming method of the on-orbit continuous forming apparatus for composite material truss structures.

[0143] The forming method of this invention includes the following steps:

[0144] Step S100: Control the connection function module to connect the longitudinal beam composite material strip, the transverse beam composite material strip, and the cable composite material;

[0145] Step S200: Control the cable-stayed cable supply module to supply cable-stayed composite material, control the longitudinal beam supply module to supply longitudinal beam composite material strip, and control the connection function module to connect the longitudinal beam composite material strip;

[0146] Step S300: After the longitudinal beam composite material strip is supplied to a preset length, stop controlling the longitudinal beam feeding module to supply the longitudinal beam composite material strip, and control the cross beam feeding module to supply the cross beam composite material strip. Also, control the cable feeding module to move the cable composite material, and then control the connection function module to connect the longitudinal beam composite material strip, the cross beam composite material strip, and the cable composite material.

[0147] Step S400: Continue executing the steps of controlling the cable-stayed cable supply module to supply cable-stayed composite material, controlling the longitudinal beam supply module to supply longitudinal beam composite material strip, and controlling the connection function module to connect the longitudinal beam composite material strip until the longitudinal beam composite material strip is supplied to the target length, thus obtaining a composite material truss structure.

[0148] Specifically, the process begins by connecting the longitudinal beam composite material strips, the crossbeam composite material strips, and the stay cable composite material to form the base of the prism. Then, the stay cable supply module supplies the stay cable composite material, the longitudinal beam supply module supplies the longitudinal beam composite material strips, and the crossbeam supply module stops supplying the crossbeam composite material strips. The connecting module then connects the longitudinal beam composite material strips to form a longitudinal beam of a certain length. Next, the longitudinal beam supply module stops supplying the longitudinal beam composite material strips, the crossbeam supply module supplies the crossbeam composite material strips, and the stay cable supply module moves the stay cable composite material. The connecting module then connects the longitudinal beam composite material strips, the crossbeam composite material strips, and the stay cable composite material. Finally, steps S200-S400 are repeated until the longitudinal beam reaches the target length, resulting in a composite truss structure. The target length is on the order of 0.1-10 kilometers, significantly longer than the preset length, making the composite truss structure a large-scale aerospace structure.

[0149] It should be understood that the application of the present invention is not limited to the examples above. Those skilled in the art can make improvements or modifications based on the above description, and all such improvements and modifications should fall within the protection scope of the appended claims.

Claims

1. An on-orbit continuous forming device for composite material truss structures, characterized in that, include: A frame support structure, wherein the frame support structure is prismatic in shape; Multiple longitudinal beam feeding modules are located at the rear end of the side edges in the frame support structure; Multiple beam feeding modules are located at corresponding positions on the side of the frame support structure; Multiple cable-stayed bridge feeding modules are located at the front end of the side edge and the corresponding position of the bottom edge in the frame support structure, respectively; Multiple connection functional modules are located at the corresponding positions of the vertices in the frame support structure; The connection module is configured to connect the longitudinal beam composite material strip supplied by the longitudinal beam supply module, the crossbeam composite material strip supplied by the crossbeam supply module, and the cable-stayed composite material supplied by the cable-stayed supply module to form a composite material truss structure. The longitudinal beam composite material strip includes an upper composite material strip and a lower composite material strip; the longitudinal beam feeding module includes: The folding extension arm and the connecting device are both located at the rear end of the side edge in the frame support structure; Both the upper composite material strip roll and the lower composite material strip roll are disposed on the folding extension arm; The upper composite material strip is flattened and wound onto the upper composite material strip roll; The lower composite material strip is flattened and wound onto the lower composite material strip roll; The upper composite material strip is V-shaped in a stress-free state, and the lower composite material strip is W-shaped in a stress-free state. The edges of the upper composite material strip and the edges of the lower composite material strip are connected to form the longitudinal beams of the composite material truss structure. The connecting device is configured to connect the end of the remaining longitudinal beam composite strip and the front end of the newly added longitudinal beam composite strip. The beam feeding module includes: A drawer-type storage bin is located on the side of the frame support structure and is configured to hold the composite material strip of the crossbeam; A drive and push device is installed in the drawer-type storage box; A beam feeding pusher is located inside the drawer-type storage box and connected to the drive pushing device; The beam feeding pusher, under the drive and push device, pushes the beam composite material strip inside the drawer-type storage box.

2. The on-orbit continuous forming device for composite material truss structures according to claim 1, characterized in that, The connecting device includes: A supporting base block is provided in the frame support structure; The first and second flattening rollers are respectively disposed on both sides of the support base block; A connecting bracket is provided on the frame support structure; A connecting unit is disposed on the connecting bracket; The connecting unit is located above the supporting base block.

3. The on-orbit continuous forming device for composite material truss structures according to claim 1, characterized in that, The crossbeam composite material strip includes: a first composite material strip and a second composite material strip; Both the first composite material strip and the second composite material strip are Ω-shaped; The first composite material strip and the second composite material strip protrude to both sides respectively, and the edges of the first composite material strip and the edges of the second composite material strip are connected.

4. The on-orbit continuous forming device for composite material truss structures according to claim 1, characterized in that, The cable-stayed bridge feeding module includes: The cable coil, the material switching device, and the constant tension control mechanism are sequentially arranged at the front end of the side edge of the frame support structure; A reciprocating arrangement mechanism is installed at the corresponding position of the bottom edge of the frame support structure; The cable-stayed composite material is wound around the cable-stayed material roll; The switching device is configured to connect the remaining cable-stayed composite material with the newly added cable-stayed composite material; The constant tension control mechanism is configured to adjust the output tension of the cable-stayed composite material; The reciprocating arrangement mechanism is configured to move along the bottom edge direction of the frame support structure to adjust the position of the cable-stayed composite material.

5. The on-orbit continuous forming device for composite material truss structures according to claim 4, characterized in that, The reciprocating arrangement mechanism includes: Both the lead screw and the guide rod are located on the bottom edge of the frame support structure; The mounting head is threadedly connected to the lead screw and slides relative to the guide rod; A commutator is disposed on the frame support structure and connected to the lead screw; A variable-height diagonal brace is provided in the frame support structure and configured to adjust the height of the arrangement head; The arrangement head is configured to connect the cable-stayed composite material.

6. The on-orbit continuous forming apparatus for composite material truss structures according to any one of claims 1 to 5, characterized in that, The connection function module includes: A position control device is installed at the position corresponding to the vertex in the frame support structure; A connection unit is disposed in the position control device; The position control device is configured to adjust the position of the connecting unit; The connecting unit is configured to connect the longitudinal beam composite strip, the transverse beam composite strip, and the cable composite material.

7. The on-orbit continuous forming apparatus for composite material truss structures according to any one of claims 1 to 5, characterized in that, The framework support structure includes: A central load-bearing cylinder, wherein the central load-bearing cylinder is prismatic in shape; Several supporting uprights are fitted onto the outside of the central load-bearing cylinder; Several mounting plates are disposed on the supporting upright plate.

8. A forming method for an on-orbit continuous forming apparatus for composite material truss structures as described in any one of claims 1 to 7, characterized in that, Including the following steps: The control connection function module connects the longitudinal beam composite material strip, the transverse beam composite material strip, and the cable composite material; The control module supplies cable-stayed composite material to the cable-stayed cable, the control module supplies longitudinal beam composite material strip to the longitudinal beam, and the control module connects the longitudinal beam composite material strip. After the longitudinal beam composite material strip is supplied to a preset length, the longitudinal beam feeding module stops supplying the longitudinal beam composite material strip, and the crossbeam feeding module supplies the crossbeam composite material strip. The cable feeding module moves the cable composite material, and the connection function module connects the longitudinal beam composite material strip, the crossbeam composite material strip, and the cable composite material. Continue executing the steps of controlling the cable-stayed cable supply module to supply cable composite material, controlling the longitudinal beam supply module to supply longitudinal beam composite material strip, and controlling the connection function module to connect the longitudinal beam composite material strip, until the longitudinal beam composite material strip is supplied to the target length, thus obtaining a composite material truss structure.

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