On-Orbit Additive Assembly for Modular Spacecraft Deployment
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Solution Overview
Problem
Current spacecraft deployment methods are costly, time-consuming, and pose risks due to the need for high-strength mechanical structures and materials for launch, which are not necessary in the microgravity environment of space.
Innovation Solution
A space assembly system that combines on-orbit additive manufacturing with ground-based launch, featuring a physical subsystem with an additive manufacturing unit, space robot, raw material bin, and communication subsystem, along with a digital twin subsystem for remote monitoring and control.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If spacecraft are manufactured on the ground and launched to space, then the spacecraft can be deployed with high reliability, but the launch costs increase and the deployment cycle lengthens
Solution Approach 1:
The spacecraft is divided into modular components that can be manufactured separately on the ground and assembled in space. This allows parallel manufacturing of multiple modules, reducing the overall deployment cycle while maintaining reliability through modular assembly procedures.
Solution Approach 2:
Spacecraft modules are pre-manufactured and prepared on the ground before launch. This preliminary manufacturing action allows extensive testing and preparation to occur on Earth, ensuring reliability while the actual deployment time in space is minimized through pre-prepared components.
2Strength
If spacecraft are manufactured on the ground and launched, then the spacecraft structure can meet launch requirements, but the launch vehicle capacity limits the spacecraft size and weight
Solution Approach 1:
The spacecraft is segmented into multiple modules that can be manufactured to optimal weight and strength ratios for each function. This modular approach allows the total spacecraft weight to be optimized while meeting structural requirements, as each module can be independently designed and assembled in space without launch vehicle size constraints.
Solution Approach 2:
The spacecraft structure transitions from static ground-manufactured components to dynamic in-orbit assembly. Modules are launched separately and assembled in space, allowing the final spacecraft configuration to exceed launch vehicle capacity limits while maintaining structural integrity through controlled assembly operations.
3Strength
If high-strength mechanical structures are used for launch, then the spacecraft can withstand launch forces, but the manufacturing costs increase
Solution Approach 1:
The spacecraft is divided into modules that can be manufactured with optimized material usage for each specific function. This reduces the need for over-engineering with high-strength materials throughout the entire structure, as each module can be designed with appropriate material properties for its specific operational requirements, lowering overall manufacturing costs.
Solution Approach 2:
Different modules of the spacecraft are manufactured with locally optimized material properties and structural characteristics suited to their specific functional requirements. This eliminates the need to use high-strength materials throughout the entire spacecraft, reducing manufacturing costs while maintaining adequate strength where needed through targeted material selection in each module.
4Productivity
If finished spacecraft are launched from the ground, then the deployment can be completed in one launch, but the frequency and timeliness of spacecraft deployment are limited
Solution Approach 1:
The spacecraft is segmented into modular components that can be manufactured and prepared independently on the ground. This enables multiple modules to be ready for launch simultaneously, increasing deployment frequency and timeliness. The modular structure also provides adaptability, allowing different combinations of modules to be assembled in space based on specific mission requirements.
Solution Approach 2:
The modular spacecraft architecture employs universal interfaces and standardized components that can be assembled in various configurations. This multi-functionality allows the same set of modules to serve different mission purposes, increasing both deployment efficiency and adaptability to varying mission requirements without requiring separate complete spacecraft for each mission type.
Data Source
AI summary
Some embodiments of the disclosure disclose a space assembly system based on fusion of on-orbit additive manufacturing and ground-based launch. In some examples, an operator establishes a space manufacturing center to achieve on-orbit manufacturing of spacecraft structural components and assembles the components manufactured on orbit with spacecraft enabling modules launched from the ground to form a target spacecraft. The system includes a physical subsystem, a digital twin subsystem, and a communication subsystem. The physical subsystem includes a control unit, a communication unit, a sensor unit, an imaging and positioning device, a data storage unit, a data processing unit, an additive manufacturing unit, a space robot unit, and a raw material bin. The digital twin subsystem remotely monitors the physical subsystem. The communication subsystem establishes a connection between the physical subsystem and the digital twin subsystem and a connection between all units and devices of the physical subsystem.