Integral Additive Manufactured Actuation Device for Spacecraft Deployment

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Solution Overview

Problem

Existing deployment mechanisms for spacecraft appendages, such as solar array panels and antenna reflectors, are costly and unreliable due to their complexity, which includes multiple springs, tensioning wires, hinges, and structural components.

Innovation Solution

An integral, additively manufactured actuation device with a shaped structural member and a helical torsion spring, featuring a coupling feature for secure attachment to spacecraft appendages, providing a cost-effective and reliable deployment mechanism.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If traditional deployment mechanisms with multiple springs, tensioning wires, hinges, and structural components are used, then the deployment function can be achieved, but the device complexity and cost increase significantly

Engineering Contradiction:

Improvedeployment reliabilityVSAvoidmechanism complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The patent combines multiple separate components (structural member, torsion spring, coupling features) into a single integral actuation device manufactured via additive manufacturing. This merging eliminates the need for multiple discrete springs, tensioning wires, and hinges while maintaining the deployment function, directly reducing device complexity and assembly requirements.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The integral actuation device performs multiple functions simultaneously: the shaped structural member provides structural support, the helical torsion spring provides deployment force, and the coupling features enable attachment to spacecraft appendages. This multi-functionality in a single component reduces the overall number of parts needed in the deployment mechanism.

Inventive Principle:

Principle #6Universality (Multi-functionality)

2Reliability

If traditional deployment mechanisms with multiple components are used, then the deployment function can be achieved, but the manufacturing cost increases due to multiple parts and assembly requirements

Engineering Contradiction:

Improvedeployment reliabilityVSAvoidmanufacturing cost

Core Design Contradiction:

ReliabilityVSEase of manufacture

Solution Approach 1:

By merging multiple components into a single integral actuation device, the patent eliminates the need for procuring, inventorying, and assembling multiple separate parts. The additive manufacturing process allows complex geometries to be produced as single pieces, reducing manufacturing steps and assembly labor costs while maintaining functional reliability.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The patent utilizes additive manufacturing technology to produce the integral actuation device, representing a parameter change in the manufacturing process. This manufacturing method enables cost-effective production of complex geometries that would be difficult or expensive to manufacture using traditional subtractive or assembly-based methods.

Inventive Principle:

Principle #35Parameter changes

3Productivity

If traditional deployment mechanisms with multiple discrete components are used, then the deployment function can be achieved, but the number of parts and assembly steps increase

Engineering Contradiction:

Improvedeployment efficiencyVSAvoidnumber of components

Core Design Contradiction:

ProductivityVSDevice complexity

Solution Approach 1:

The patent merges multiple discrete components into a single integral actuation device, directly reducing the number of parts that need to be manufactured, inventoried, and assembled. This simplification improves productivity by reducing assembly steps and potential failure points while maintaining the deployment function.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

While the actuation device itself is integral, the patent maintains segmentation in the coupling features that allow the device to interface with spacecraft appendages. The coupling features are designed as integrated elements of the actuation device, providing connection functionality without requiring separate fasteners or mounting hardware.

Inventive Principle:

Principle #1Segmentation

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 solution enables controlled and efficient deployment of spacecraft appendages with reduced complexity and cost, improving reliability and scalability for various spacecraft configurations.

Implementation Method 1

a flexible portion comprising a helical torsion spring

Methodology Applied

Scientific EffectTorsion spring: Torsion Spring

Implementation Method 2

a distal portion of the torsion spring may be flexibly disposed with respect to the rigid portion

Methodology Applied

Scientific EffectElasticity: Elasticity

Data Source

PatentUS11858665B1Deployment mechanism with integral actuation device

Publication Date: 2024.01.02 LANTERIS SPACE LLC

AI summary

An apparatus includes an integral, additively manufactured, actuation device having a rigid portion comprising a shaped structural member and a flexible portion comprising a helical torsion spring. In a spacecraft application, a spacecraft appendage may be coupled with a deployment mechanism, the deployment mechanism including at least one integral, additively manufactured, actuation device having a rigid portion comprising a shaped structural member and a flexible portion comprising a helical torsion spring.