Dual-Manifest Spacecraft Core Structure with Common Electronics Module
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Solution Overview
Problem
The high cost and complexity of launching multiple spacecraft on a single launch vehicle due to differing structural configurations for upper and lower spacecraft, which incur additional design, manufacturing, and testing requirements, leading to increased costs and schedules.
Innovation Solution
A dual-manifest launch configuration using upper and lower core structures with similar inner diameters, where the upper cylinder is a composite sandwich and the lower cylinder is a solid laminate of fiber-reinforced polymer matrix material, both coupled to a common electronics module with reinforcing rings, allowing for interchangeable manufacturing and testing processes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If different structural configurations are used for upper and lower spacecraft, then each spacecraft can be optimized for its specific requirements, but manufacturing costs and schedule increase due to unique design, analysis, manufacturing, and testing requirements
Solution Approach 1:
The patent applies universality by designing the upper and lower core structures with substantially similar outer diameters and interface locations, allowing both spacecraft to use common manufacturing tooling, assembly fixtures, ground support equipment, and testing procedures. This multi-functional design enables the same structural configuration to serve both spacecraft despite their different mission requirements
Solution Approach 2:
The patent applies local quality by allowing the internal structural characteristics (such as wall thickness, material distribution, or internal reinforcement) to differ between upper and lower core structures while maintaining similar external dimensions and interface locations. This enables each spacecraft to have optimized internal structures for its specific load requirements while still benefiting from common manufacturing processes
2Adaptability or versatility
If different structural configurations are used for upper and lower spacecraft, then each spacecraft can be optimized for its specific requirements, but ground support equipment and assembly fixtures must be different, increasing cost
Solution Approach 1:
The patent applies universality by standardizing the outer diameter and interface locations of both core structures, which enables the use of common ground support equipment, assembly fixtures, and integration procedures for both upper and lower spacecraft, thereby reducing manufacturing costs
3Quantity of substance
If the upper spacecraft is positioned far from the launch vehicle interface, then dual-manifest configuration is achieved, but high bending loads are induced on the lower spacecraft structure due to aerodynamic turbulence
Solution Approach 1:
The patent applies composite materials by constructing the core structures from composite materials that provide high strength-to-weight ratios, enabling the structures to resist the high bending loads induced by aerodynamic turbulence while maintaining the dual-manifest configuration with the upper spacecraft positioned at a greater distance from the launch vehicle interface
Data Source
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AI summary
A spacecraft may include an upper core structure (148) or a lower core structure (168). The upper core structure (148) may include an upper cylinder (150) for supporting an upper spacecraft (146) of a dual-manifest launch configuration. The lower core structure (168) may include a lower cylinder (170) for supporting a lower spacecraft (166) with the upper cylinder (150) mounted on top of the lower cylinder (170). The upper cylinder (150) may have an upper cylinder inner diameter that may be substantially similar to the lower cylinder inner diameter.