Helical Deployable Mast Assembly for High-Stiffness Space Structures
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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 increases costs and limits size.
Innovation Solution
A system for deploying a deployable mast using an elongate band that transitions from a stowed configuration to a helical, longitudinal configuration, secured by connectors and welded together by a welder that rotates about the axis, forming a cylindrical structure with high strength capabilities.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If manual assembly methods are used in space, then structures can be assembled, but the size of structures is limited and manufacturing/shipping costs increase
Solution Approach 1:
The structure is divided into multiple modular segments that can be manufactured separately on Earth and then assembled in space. Each segment contains standardized connection interfaces that enable automated or semi-automated assembly, reducing the need for complex manual assembly operations while allowing the construction of large-scale structures.
2Productivity
If automated deployment systems are used, then deployment speed increases, but the structures lack sufficient strength and stiffness when larger structures are needed
Solution Approach 1:
The modular segments are pre-assembled and pre-tested on Earth before launch, with connection interfaces prepared in advance. This preliminary action allows for rapid deployment in space while ensuring that each module meets strength and stiffness requirements before being integrated into the larger structure.
Solution Approach 2:
The patent employs composite material construction for the modular segments, combining materials with high strength-to-weight ratios. This enables the structure to achieve sufficient strength and stiffness for large-scale applications while maintaining the capability for rapid automated deployment.
3Volume of stationary object
If larger structures are assembled in space, then the required volume for launch is reduced, but manual assembly costs and complexity increase
Solution Approach 1:
Multiple modular segments are nested within each other during launch, with smaller segments contained within larger ones. This nesting arrangement minimizes the volume required in the launch vehicle while maintaining the capability to assemble large structures in space through automated or semi-automated processes.
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 large, rigid structures with high load-bearing capabilities, allowing for efficient assembly and deployment of structures such as space habitats, while reducing manufacturing and shipping costs.
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.