Deployable Helical Mast Joints for High-Strength Space Structures
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Solution Overview
Problem
Existing deployable structures lack sufficient strength and stiffness for larger applications, particularly when supporting high-mass payloads, and require manual assembly in space, which increases costs and limits structure size.
Innovation Solution
A deployment system using a stowed elongate band that transitions into a helical, longitudinal configuration, secured by connectors and welded together by a rotating welder, forming a deployable mast with high strength capabilities.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If deployable structures are manually assembled in space, then structure size is limited and assembly costs increase, but structure strength and stiffness are insufficient for larger applications
Solution Approach 1:
The structure is divided into multiple modular segments that can be deployed sequentially from a compact stowed configuration. Each segment contains integrated connection features that automatically engage with adjacent segments during deployment, eliminating the need for manual assembly operations in space while maintaining structural integrity through standardized mechanical interfaces.
Solution Approach 2:
Connection features such as protrusions and receptacles are pre-configured on the band segments before deployment. The band segments are pre-aligned and pre-positioned so that when deployed, the connection features automatically engage without requiring manual intervention, thereby reducing assembly complexity while ensuring proper structural connections.
2Strength
If deployable structures use simple mechanical connections, then assembly is easier, but strength and stiffness are insufficient for high-mass payloads
Solution Approach 1:
Multiple connection functions are merged into integrated connection features that combine mechanical engagement, alignment, and structural reinforcement in single components. The protrusions and receptacles are designed to perform multiple functions simultaneously: providing structural strength for high-mass payloads, ensuring precise alignment during deployment, and enabling automatic engagement without manual intervention.
Solution Approach 2:
The connection features utilize composite construction combining different material properties within the same component. The band segments and connection features may incorporate composite materials that provide both the structural strength needed for high-mass payloads and the manufacturing ease required for automated assembly, such as fiber-reinforced polymers or metal-matrix composites.
3Strength
If the elongate band is welded during deployment, then structural strength increases, but the welding system complexity increases
Solution Approach 1:
The welding system is designed to perform welding operations automatically during the deployment process without requiring external intervention. The welder is integrated into the deployment mechanism and activates automatically when the band segments are positioned, using the deployment motion itself to facilitate the welding process. This self-service approach increases joint strength while minimizing the added complexity by making the welding system part of the existing deployment infrastructure.
4Strength
If the structure is designed for large size, then payload capacity increases, but stowed volume requirements increase
Solution Approach 1:
The deployable structure utilizes a nested configuration where the elongate band is wound in a spiral or helical pattern around a central axis during stowed storage. Multiple band segments are nested within each other in a compact arrangement, similar to nested dolls, allowing the large structure to be stored in a small volume. During deployment, the nested segments are sequentially unrolled or extended to achieve the full large-size configuration capable of supporting high-mass payloads.
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
Enables the deployment of rigid, cylindrical structures with high strength and stiffness, allowing for larger space habitats and supporting payloads, while reducing assembly costs and size constraints.
Implementation Method 1
The welding system includes a welder configured to move relative to the axis while welding together adjacent edges of the elongate band as the elongate band transitions from the stowed configuration to the deployed configuration
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.