Deployable Helical Mast Assembly for Stiff Space Habitats
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Solution Overview
Problem
Existing deployable structures lack sufficient strength and stiffness, especially when larger structures are needed or when supporting payloads with high mass, and they often require manual assembly in space, which limits size and increases manufacturing and shipping costs.
Innovation Solution
A deployment system using an elongate band stored in a spiral configuration on a storage reel, guided helically to form a cylindrical mast, with adjacent edges secured by connectors and welded together by a rotating welder, forming a deployable mast that can be up to 20 meters long, and multiple masts can connect large rings to create structures like space habitats.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If deployable structures are designed to be larger and support higher mass payloads, then the strength and stiffness requirements increase, but existing deployable structures lack sufficient strength and stiffness
Solution Approach 1:
The deployable structure is divided into multiple modular bay segments that can be individually manufactured and then assembled. Each bay contains standardized components including struts, panels, and connection nodes. This segmentation allows the structure to achieve high strength and stiffness through precise manufacturing of individual segments while enabling scalability to support various payload masses by adding or configuring different numbers of bays.
2Ease of manufacture
If structures are assembled manually in space, then flexibility in assembly is maintained, but the size of structures is limited and manufacturing and shipping costs increase
Solution Approach 1:
Complex structural components such as bays, panels, and connection nodes are pre-manufactured on Earth with high precision using automated manufacturing processes. These pre-manufactured modules are then transported to space and assembled using standardized interfaces. This preliminary action on Earth reduces manufacturing costs through economies of scale and automated production, while enabling the construction of very large structures in space by combining multiple modules.
3Length of moving object
If traditional deployable structures are used, then deployment capability is achieved, but sufficient strength and stiffness are not attained when larger structures are needed
Solution Approach 1:
The structure employs composite material construction within its components, particularly in the panels and struts. The panels utilize composite sandwich constructions with high-strength face sheets and lightweight core materials, while struts incorporate composite tubular sections. These composite materials provide exceptional strength-to-weight ratios, enabling the structure to achieve both great length and sufficient structural strength without excessive mass.
4Productivity
If manual assembly methods are used in space, then assembly flexibility is maintained, but productivity and efficiency decrease
Solution Approach 1:
The assembly system is segmented into standardized modules with uniform connection interfaces. Each bay module contains pre-assembled subcomponents that connect through standardized nodes and fastening mechanisms. This segmentation enables workers to assemble the structure in a repetitive, systematic manner rather than dealing with unique custom connections for each component, dramatically improving assembly efficiency while maintaining manageable system complexity through standardization.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The system enables the deployment of strong and stiff structures that can support high payloads, reducing assembly costs and allowing for larger space habitats to be built efficiently, with the ability to form structures up to 70 meters in length.
Implementation Method 1
A welding system may weld adjacent edges of the band as it deploys
Data Source
AI summary
Deployable structures are described, in particular linearly-deployable structures, such as masts or booms. The masts may be stowed for transport and then deployed at their destination in space or on earth. A deployment system includes a storage reel storing a stowed elongate band. A drive mechanism biases and guides the band helically out of the storage reel to form an elongated mast. Adjacent edges of the deployed band may secure together using openings and corresponding protrusions, such as rivets. A welding system may use a rotating welder to weld adjacent edges of the band as it deploys. The band may be formed of multiple band segments attached together by connectors such as doublers. Protrusions such as rivets or other fasteners may attach the connectors to opposing sides of the band segments. A cylindrical space habitat or other macrostructure may be formed using multiple deployable masts that connect large rings.