Modular Payload Dispenser Joints for Faster Satellite Integration
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Solution Overview
Problem
The integration of multiple satellites onto a launch vehicle dispenser is a time-consuming process, typically requiring many hours or even weeks, due to the complexity and number of support structures involved.
Innovation Solution
The payload dispenser employs a simplified joint design with angled clamp flanges and panel flanges that minimize the number of joints required, allowing for efficient assembly and disassembly, while utilizing structural mass for stiffness and enabling modular design for easier maintenance and transportation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional support structures and multiple joints are used to assemble panels, then structural stability and load transfer capability are improved, but integration time and device complexity increase significantly
Solution Approach 1:
The clamp flange integrates multiple functions into a single component: it provides structural support, creates the joint connection, and enables load transfer between panels. This merging of functions reduces the number of separate parts and assembly steps, directly reducing integration time while maintaining structural stability
Solution Approach 2:
The clamp flange is designed with pre-configured angled surfaces and attachment features that enable immediate connection upon assembly. The geometry is prepared in advance to automatically align and secure panels, eliminating the need for complex alignment procedures and reducing assembly time
2Strength
If multiple joints are used to ensure sufficient load transfer capability between panels, then structural reliability is improved, but the number of parts and assembly complexity increase
Solution Approach 1:
The clamp flange combines support structure, connection mechanism, and load transfer path into a single integrated component. This eliminates the need for multiple separate joints while maintaining sufficient load transfer capability through the engineered geometry and material properties of the clamp flange itself
Solution Approach 2:
The angled surfaces of the clamp flange are designed with specific angle parameters that optimize both load transfer capability and structural stability. By carefully selecting these geometric parameters, the design achieves high strength with fewer joints, reducing overall device complexity
3Stability of the object's composition
If traditional assembly methods with multiple support structures are used, then structural mass provides sufficient stiffness, but transportation logistics and tooling requirements become more complex
Solution Approach 1:
The dispenser is divided into modular panel sections that can be manufactured and transported separately in a flat configuration. The clamp flanges enable these segmented panels to be quickly assembled into the final cylindrical structure, simplifying transportation logistics while maintaining structural stiffness through the modular design
Solution Approach 2:
The panels and clamp flanges are designed to assemble from a flat, two-dimensional configuration into a three-dimensional cylindrical structure. This dimensional transformation enables easy transportation in a compact flat state while achieving the required structural stiffness and stability in the assembled three-dimensional form
Data Source
Figure 1
Figure 2a~2c
Figure 3
AI summary
A payload dispenser (1)for a launch vehicle comprising a plurality of panels (2), wherein at least one panel (2) comprises at least one payload (3) mounted onto the panel (2). The panels (2)are attachable to each other by means of attachment means (4, 6) in form of at least one payload dispenser joint (10) whereby a self-supporting dispenser (1)is formed.