Dual ESPA Port Satellite Assembly via Pivoting Hinges
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Solution Overview
Problem
Current small satellite designs for Evolved Expendable Launch Vehicle (EELV) Secondary Payload Adapter (ESPA) ports are limited by constrained mass and volume, restricting mission usefulness and life, as they can only support a single payload and have limited flexibility in launch configurations.
Innovation Solution
The system employs a payload adaptor ring with multiple small satellite components and a pivoting hinge system, allowing components to be mounted, connected, and reassembled on-orbit, enabling the creation of a larger satellite from multiple ESPA ports, with mechanical clamp bands and flexible electrical cables for integration and communication.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If a single small satellite component is mounted on an ESPA port, then the satellite can be launched, but the payload volume and mass are constrained, limiting mission usefulness
Solution Approach 1:
The satellite system is divided into multiple separable components (first small satellite component and second small satellite component) that can be independently mounted on separate ESPA ports, then assembled in space to form a larger integrated satellite, thereby increasing total payload volume while maintaining manageable individual component sizes for launch
Solution Approach 2:
Multiple satellite components are nested within the ESPA adapter structure during launch, with each component fitting within the constrained volume of individual ports, then deployed and assembled to achieve a larger final configuration similar to nested dolls expanding to their full size
2Adaptability or versatility
If multiple small satellite components are combined on-orbit using a pivoting hinge system, then a larger satellite is created with increased capability, but the device complexity increases
Solution Approach 1:
The pivoting hinge system provides dynamic adaptability, allowing the satellite components to be connected at various angles and configurations during assembly, enabling the system to transition from a compact launch configuration to an expanded operational configuration with increased mission capability
Solution Approach 2:
The pivoting hinge system acts as an intermediary mechanical interface between separate satellite components, providing a controlled connection mechanism that enables assembly in space while managing the complexity of joining multiple independent components with precise alignment and structural integrity
3Ease of operation
If satellite components are connected with mechanical clamp bands, then the interface can be coupled and uncoupled repeatedly, but the structural complexity increases
Solution Approach 1:
The mechanical clamp band system enables self-service coupling and uncoupling operations, allowing satellite components to be connected and disconnected multiple times without requiring complex external assistance systems, thereby improving ease of operation while maintaining a manageable mechanical interface design
Data Source
Figure 1A~1D
Figure 2~3
Figure 4A~4D
AI summary
An apparatus and method are disclosed for dual Evolved Expendable Launch Vehicle (EELV) Secondary Payload Adapter (ESPA) port small satellite designs. The apparatus and method provide payload volume for larger satellites. In one or more embodiments, the apparatus and method include a plurality of small satellite components, a payload adaptor ring, and at least one pivoting hinge system. In at least one embodiment, the plurality of small satellite components includes at least one payload, one bus, and/or one solar panel. The small satellite components are mounted on the payload adaptor ring. At least one pivoting hinge system connects together at least two of the small satellite components. Upon deployment of the small satellite components from the payload adaptor ring, at least one pivoting hinge system combines together at least two small satellite components, thereby creating at least one single larger satellite.