Modular Satellite Bus Polygonal Assembly

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Solution Overview

Problem

The manufacturing of spacecraft buses is labor-intensive and costly due to their handmade nature, resulting in irregular and non-uniform structures, which limits the efficiency and quantity of satellite production, especially for CubeSats with their small size and limited internal components.

Innovation Solution

A modular satellite bus configuration comprising individual side panels forming a regular polygonal shape, allowing multiple buses to fit together efficiently, maximizing payload space in rockets, and enabling uniform and efficient manufacturing through self-mating techniques without additional support materials, using flanges and adhesives or fasteners for secure assembly.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Manufacturing precision

If handmade manufacturing techniques are used for spacecraft buses, then customization and structural integrity are achieved, but production time and cost increase significantly

Engineering Contradiction:

Improvestructural integrityVSAvoidproduction time

Core Design Contradiction:

Manufacturing precisionVSProductivity

Solution Approach 1:

The spacecraft bus is divided into multiple identical modular panels that can be manufactured separately using standardized processes. Each panel is a self-contained unit with standardized interfaces, allowing parallel production and reducing overall manufacturing time while maintaining structural integrity through consistent design.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The design transitions from custom-made continuous structures to discrete modular units with standardized dimensions and interfaces. This parameter change enables the use of automated manufacturing processes and modular assembly techniques, significantly reducing production time while maintaining structural performance through standardized design parameters.

Inventive Principle:

Principle #35Parameter changes

2Manufacturing precision

If handmade manufacturing techniques are used for spacecraft buses, then structural integrity is maintained, but manufacturing cost increases considerably

Engineering Contradiction:

Improvestructural integrityVSAvoidmanufacturing cost

Core Design Contradiction:

Manufacturing precisionVSEase of manufacture

Solution Approach 1:

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The modular panels are designed with universal interfaces and standardized features that can be used across different spacecraft bus configurations. This universality allows the same panel design to serve multiple functions and be reused in different missions, reducing development and tooling costs while maintaining structural integrity.

Inventive Principle:

Principle #6Universality (Multi-functionality)

3Manufacturing precision

If CubeSats are designed with uniform small size, then manufacturing consistency is improved, but the quantity of internal components and functionality are limited

Engineering Contradiction:

Improvemanufacturing consistencyVSAvoidfunctionality

Core Design Contradiction:

Manufacturing precisionVSAdaptability or versatility

Solution Approach 1:

The CubeSat is divided into multiple modular panels that can be manufactured with high consistency using standardized processes. Each panel contains standardized interfaces and mounting features, enabling consistent manufacturing while allowing flexible configuration of internal components to achieve desired functionality.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The design utilizes the three-dimensional space within the compact CubeSat form factor by creating modular panels that can be stacked and configured in different arrangements. This dimensional approach maximizes the use of internal volume for components while maintaining the external uniform size required for consistent manufacturing and deployment.

Inventive Principle:

Principle #17Another dimension (Dimensionality change)

4Area of stationary object

If multiple satellite buses are configured to fit together in regular polygon shape, then payload space utilization is maximized, but assembly complexity increases

Engineering Contradiction:

Improvepayload space utilizationVSAvoidassembly complexity

Core Design Contradiction:

Area of stationary objectVSDevice complexity

Solution Approach 1:

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The modular panels incorporate self-aligning features and standardized interfaces that enable automatic positioning during assembly. The panels are designed to self-mate through complementary geometric features, reducing the need for complex alignment procedures and specialized assembly tools, thereby simplifying the overall assembly process despite the multi-panel configuration.

Inventive Principle:

Principle #25Self-service

Data Source

PatentUS10689131B2Sectioned self-mating modular satellite buses

Publication Date: 2020.06.23 LOCKHEED MARTIN CORP

AI summary

A satellite configuration includes a plurality of individual satellite buses each having a number of side panels that form a polygonal shape, where the individual satellite buses collectively fit together to form the satellite configuration having a regular polygon shape. A method of producing the satellite configuration includes forming a plurality of individual satellite buses each having a polygonal shape, and fitting the individual satellite buses together to form the satellite configuration in a regular polygonal shape.