Modular Payload Release Mechanism for Reusable Launch Vehicles
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Solution Overview
Problem
Existing payload release mechanisms from launch vehicles require refurbishment after testing, are non-modular, and suffer from high kinematic angular errors due to simultaneous actuation challenges, limiting flexibility and testability.
Innovation Solution
A modular release mechanism featuring guided push-off springs integrated into a single housing with a flyaway plate and a single non-explosive actuator, allowing for preloading and independent testing without refurbishment, utilizing a preload bolt and strain gauge for precise control.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If explosive bolts or compressed gas actuators are used for payload release, then the release mechanism is simple and reliable, but the system requires refurbishment after testing and cannot be reused
Solution Approach 1:
The release mechanism is divided into separable components: a housing assembly that remains with the launch vehicle and a flyaway plate that attaches to the payload. This segmentation allows the housing with the actuator to be retained and reused, while only the flyaway plate is discarded after payload release, enabling system reusability without compromising reliability
Solution Approach 2:
The design discards only the consumable flyaway plate after payload release, while recovering and retaining the expensive actuator and housing assembly for reuse. This selective discarding approach enables multiple test cycles and missions, transforming a single-use system into a reusable one
2Object-affected harmful factors
If multiple clamp bands are used for payload release, then the mechanism is non-explosive and safer, but simultaneous actuation is difficult to achieve and high kinematic angular errors may result
Solution Approach 1:
Multiple clamp bands are replaced by a single integrated housing assembly containing one actuator that controls the release mechanism. This merging of multiple actuators into a single actuation system eliminates the timing synchronization problems and ensures precise, consistent payload release trajectory without angular errors
Solution Approach 2:
A single actuator serves as an intermediary that controls the release of multiple clamp bands through a mechanical linkage system. This intermediary approach ensures simultaneous and synchronized actuation of all clamp bands, maintaining precision while eliminating the need for multiple independent actuators
3Device complexity
If a non-modular design is used for the release mechanism, then the structure is simpler, but flexibility and adaptability are limited and no independent integration at modular level is possible
Solution Approach 1:
The release mechanism is segmented into standardized modular components: a housing assembly with actuator and a flyaway plate with attachment interfaces. These modules can be independently designed, tested, and integrated with different payloads, providing flexibility and adaptability while maintaining relatively simple individual component structures
Solution Approach 2:
The housing assembly with its standardized interfaces and actuator design serves as a universal module that can be integrated with various payload types. This multi-functional design enables the same release mechanism to be used across different missions and payload configurations, greatly enhancing flexibility without requiring complex custom designs
4Adaptability or versatility
If a single housing with integrated springs is used, then the mechanism is modular and testable without refurbishment, but the device complexity increases compared to simple explosive bolts
Solution Approach 1:
The system is segmented into a reusable housing module containing the actuator and springs, and a disposable flyaway plate. This segmentation allows the complex housing module to be independently tested and certified once, then reused multiple times, making the complexity worthwhile by enabling modularity and eliminating refurbishment requirements
Solution Approach 2:
The housing assembly with actuator and springs is pre-assembled, pre-tested, and pre-certified as a complete modular unit before integration with the payload. This preliminary action on the modular component allows it to be reused without refurbishment, as any issues are caught during initial testing rather than requiring post-mission refurbishment
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
Enables precise, flexible, and reusable payload release with reduced angular errors and no need for simultaneous actuator activation, maintaining environmental load resistance and allowing for easy system reset.
Implementation Method 1
A plurality of ejection springs are compressed between the flyaway plate and housing in an engaged position
Implementation Method 2
The bolt is torqued to a predetermined strain to withstand environmental loads and to compress the ejection springs to provide a preload for the desired potential energy
Data Source
AI summary
A modular testable release mechanism for payloads incorporates a housing and a flyaway plate separably engaged to the housing. A plurality of symmetrically positioned ejection springs are compressed between the flyaway plate and housing in an engaged position. A bolt extends through a first bore in the flyaway plate and is releasably secured in an actuator mounted on the housing symmetrically surrounded by the ejection springs. The flyaway plate is held in the engaged position with the housing by the bolt.