Nested Edge Modular Satellite Bus Assembly

Solution Overview

Problem

The handmade nature of spacecraft structural bodies, such as satellite buses, results in irregular and non-uniform components, leading to time-consuming and costly manufacturing processes, with limited internal component capacity and functionality due to their small size, as seen in CubeSats.

Innovation Solution

A modular satellite bus design featuring standardized side panels with nested longitudinal edges and flanges that form a joggle, allowing for self-mating assembly without additional support materials, using adhesives, fasteners, or pressure, and enabling easy modification of panel numbers and shapes through adjustments in the manufacturing die.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Adaptability or versatility

If handmade techniques are used to manufacture spacecraft buses, then customization and adaptability are improved, but manufacturing time and cost increase significantly

Engineering Contradiction:

ImprovecustomizationVSAvoidmanufacturing time

Core Design Contradiction:

Adaptability or versatilityVSProductivity

Solution Approach 1:

The spacecraft bus is divided into multiple identical side panels that can be manufactured separately using standardized techniques, then assembled together. This segmentation allows for efficient batch production of individual panels while maintaining the ability to customize the overall bus configuration by varying the number and arrangement of panels.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The side panels are designed with universal features including standardized flanges and joggles that can be used across different panel configurations. These universal elements enable the same basic panel design to serve multiple functions and be assembled into various bus shapes and sizes, reducing the need for custom manufacturing.

Inventive Principle:

Principle #6Universality (Multi-functionality)

2Adaptability or versatility

If handmade techniques are used to manufacture spacecraft buses, then customization and adaptability are improved, but manufacturing cost increases significantly

Engineering Contradiction:

ImprovecustomizationVSAvoidmanufacturing cost

Core Design Contradiction:

Adaptability or versatilityVSEase of manufacture

Solution Approach 1:

The spacecraft bus is divided into multiple identical side panels that can be manufactured separately using standardized techniques, then assembled together. This segmentation allows for efficient batch production of individual panels while maintaining the ability to customize the overall bus configuration by varying the number and arrangement of panels.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

Instead of custom manufacturing each bus, the invention uses copying by creating identical side panels that can be repeatedly manufactured using the same mold or die. These copied panels are then assembled into different bus configurations, significantly reducing tooling costs and manufacturing complexity.

Inventive Principle:

Principle #26Copying

3Manufacturing precision

If CubeSat size is used, then manufacturing consistency is improved, but internal component capacity and functionality are limited

Engineering Contradiction:

Improvemanufacturing consistencyVSAvoidinternal component capacity

Core Design Contradiction:

Manufacturing precisionVSVolume of stationary object

Solution Approach 1:

The spacecraft bus is divided into multiple identical side panels that can be manufactured separately using standardized techniques, then assembled together. This segmentation allows for efficient batch production of individual panels while maintaining the ability to customize the overall bus configuration by varying the number and arrangement of panels.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The side panels feature nested flange and joggle structures where one panel's flange fits into another panel's joggle, creating interlocking joints. This nesting mechanism provides precise alignment and consistent manufacturing tolerances while enabling modular assembly that can scale to larger sizes beyond traditional CubeSat dimensions.

Inventive Principle:

Principle #7Nested doll (Nesting)

Data Source

PatentUS10538341B1Self-mating modular satellite bus

Publication Date: 2020.01.21 LOCKHEED MARTIN CORP

AI summary

A self-mating modular satellite bus includes a plurality of side panels each having a front surface flanked by a first longitudinal edge and a second longitudinal edge, wherein the first longitudinal edge of each side panel is nested with the second longitudinal edge of an adjacent side panel. The longitudinal edges, when superimposed, form a joggle. A method of producing the modular satellite bus includes forming a plurality of the panels, aligning the first longitudinal edge of each side panel with the second longitudinal edge of an adjacent side panel, such that the first longitudinal edge of each side panel is nested with the second longitudinal edge of the adjacent side panel, and securing the first longitudinal edge of each side panel to the second longitudinal edge of the adjacent side panel.