5.5K Balloon Rotator Weight Reduction via Titanium Alloy
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Solution Overview
Problem
Existing rotators for balloon missions are over-designed, leading to excessive weight and reduced payload capacity, which limits instrumentation and flight duration.
Innovation Solution
Design of a 5.5K Rotator that is 33% lighter, using titanium alloy components, 3D-printed brackets, and a simplified motor frame, with a slip ring option, to support a 5,500 lbs. payload and withstand 10G axial termination load factor, while being cost-effective and easier to assemble.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If the legacy rotator design is used, then the system can support maximum payload of 8,000 lbs and withstand 10G axial termination load factor, but the weight is excessive at 124 lbs which reduces payload capacity
Solution Approach 1:
The patent changes the material parameter from traditional aluminum or steel to titanium alloy, which has a higher strength-to-weight ratio. This allows the rotator to maintain the required 10G axial termination load factor and 5,500 lbs payload capacity while reducing weight from 124 lbs to 83 lbs (33% reduction). The titanium alloy enables the same structural strength with significantly less mass.
Solution Approach 2:
The patent employs titanium alloy as a composite material solution that combines the high strength requirements with weight reduction needs. The titanium alloy construction allows the rotator to meet both the 10G load factor requirement and the reduced weight target, effectively creating a composite solution that addresses both contradictory requirements simultaneously.
2Reliability
If the legacy rotator design is used, then the system is robust and reliable, but the cost is higher and assembly is more difficult
Solution Approach 1:
The rotator is divided into modular segments including the motor assembly, slip ring assembly, bearing housing, and mounting interface. Each module can be independently manufactured, tested, and assembled. The motor housing, slip ring housing, and bearing housing are separate components that bolt together, allowing for easier manufacturing and assembly while maintaining system reliability through modular redundancy and standardized interfaces.
3Weight of moving object
If the rotator weight is reduced to increase payload capacity, then more instrumentation can be added, but the structural integrity must be maintained under 10G load factor
Solution Approach 1:
The patent utilizes the superior strength-to-weight ratio of titanium alloy to reduce rotator weight while maintaining structural integrity. The material parameter change allows the structure to be 33% lighter yet still withstand the 10G axial termination load factor and support 5,500 lbs payload, effectively resolving the trade-off between weight reduction and structural strength.
Data Source
AI summary
The present invention relates to a novel rotator for a standardized coarse azimuth-pointing system for a balloon-borne platform—either zero pressure or Super Pressure Balloons (SPB)—with a maximum suspended payload of 5,500 lbs. The 5.5K Rotator novel shaft design, bearings, motor, and housing, result in a weight of the rotator being decreased by 33% from existing legacy rotators. The present invention achieved a 24% parts reduction from existing legacy rotators, and has the advantages of lighter weight, reusability, cost-effectiveness, machinability, and ease of assembly.