Modularized Feed Array for Spacecraft RF Systems
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Solution Overview
Problem
Conventional feed arrays for spacecraft are difficult to repair and manufacture due to their highly integrated components, which leads to challenges in compactness, low mass, and high data rate capacity, especially in geosynchronous orbit altitudes.
Innovation Solution
A modularized feed array arrangement featuring a structural panel, RF radiating elements, waveguides, and fabricated modules with RF switches, amplifiers, and manifold panels with RF choke joints, allowing for mechanical and electrical independence of modules, easy installation, and thermal management using heat pipes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of repair
If components are mechanically tied together and spaced far apart to allow reworkability, then ease of repair is improved, but mass and volume increase
Solution Approach 1:
The feed array is divided into multiple independent modules, each containing complete functional components (amplifiers, switches, waveguides, radiating elements). This segmentation allows individual modules to be replaced without affecting other modules, providing ease of repair while maintaining compact spacing between components within each module.
Solution Approach 2:
Components within each module are arranged in a three-dimensional configuration rather than being spaced far apart in a single plane. The waveguides connect amplifiers to radiating elements through spatial routing, allowing compact integration while maintaining electrical connectivity and thermal management pathways.
2Weight of stationary object
If components are highly integrated in conventional feed arrays, then mass and volume are reduced, but ease of manufacture and repair deteriorate
Solution Approach 1:
The system is divided into standardized modules that can be manufactured independently and then assembled. Each module contains a complete set of components (amplifiers, RF switches, waveguides, radiating elements) that can be tested and validated separately before integration into the full feed array, simplifying the overall manufacturing process.
Solution Approach 2:
Individual modules are pre-assembled, tested, and validated before being integrated into the complete feed array system. This preliminary preparation of modular units simplifies the final assembly process and reduces manufacturing complexity by breaking down the large-scale integration problem into smaller, manageable sub-assemblies.
3Manufacturing precision
If sequential installation of components is used in conventional feed arrays, then manufacturing precision is maintained, but productivity decreases
Solution Approach 1:
The feed array is segmented into independent modules that can be manufactured and tested separately, then installed simultaneously in parallel. Each module maintains its internal component precision through dedicated assembly processes, while the overall system productivity increases by eliminating sequential installation constraints between different component groups.
Solution Approach 2:
Multiple modules are prepared in advance with all their internal components pre-assembled and precision-aligned. This preliminary preparation allows the modules to be installed simultaneously in the final system integration step, maintaining manufacturing precision within each module while dramatically improving overall installation productivity through parallel processing.
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 modular design facilitates easier repair, reconfiguration, and parallel installation, resulting in a compact, low-mass feed array with increased data rate capacity and reduced mass and volume, addressing the challenges of conventional feed arrays.
Implementation Method 1
at least one module includes one or more heat pipes thermally coupled with at least one of the plurality of amplifiers
Data Source
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AI summary
A modularized feed array arrangement includes a plurality of radio frequency (RF) radiating elements, a plurality of waveguides positioned inboard of the plurality of RF radiating elements, each RF radiating element being electrically coupled with an outboard portion of one or more of the waveguides; and a plurality of modules, each module including a plurality of RF switches, a plurality of amplifiers, and a manifold panel that includes a plurality of RF choke joints. An inboard portion of each RF switch is electrically coupled with a respective amplifier. Each RF choke joint includes a proximal portion electrically coupled with an outboard portion of a respective one of the RF switches and a distal portion electrically coupled with an inboard portion of a respective one of the waveguides.