3D Printed Spacecraft Separation Locking Component
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Current connector systems for spacecraft stage separation, such as V-bands and explosive frangible joints, require high tension and result in significant weight, complexity, and limited testing reliability due to the use of explosives and high shock release, necessitating a more efficient and cost-effective solution.
Innovation Solution
A non-explosive connector assembly utilizing a 3-D printed integral locking component with a central ring and leaf elements that can be rotated to tension and release, reducing the number and cost of parts and simplifying assembly through additive manufacturing, allowing for repeated testing and deployment without shock.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional V-band connector systems are used with high tension clampbands, then reliable connection and separation is achieved, but the system weight increases substantially and shock effects during separation become excessive
Solution Approach 1:
The connector system is divided into multiple discrete clamp elements distributed around the circumference, each independently engaging with the flange. This segmentation allows the connection function to be distributed rather than concentrated in a single high-tension band, reducing overall system weight while maintaining reliable connection through multiple contact points.
Solution Approach 2:
The invention replaces the explosive bolt-cutter mechanism with a purely mechanical release system using cam-actuated levers. This substitution eliminates the need for high-tension clampbands and explosive charges, significantly reducing system weight while maintaining reliable separation through controlled mechanical action on the clamp elements.
2Weight of moving object
If explosive frangible joints are used for separation, then weight is reduced compared to V-bands, but the destructive nature prevents testing of actual flight components
Solution Approach 1:
The invention converts the potentially harmful explosive separation method into a beneficial non-destructive mechanical separation system. By using cam-actuated levers to mechanically release the clamps, the system achieves separation without destruction, allowing flight-quality components to be tested repeatedly without degradation from explosive forces.
Solution Approach 2:
The mechanical release system allows clamps and connector components to be recovered intact after separation, enabling repeated testing and validation of flight-quality hardware. This contrasts with explosive methods that destroy components, preventing their recovery and reuse for testing purposes.
3Strength
If high tension is applied to clampband for secure connection, then connection strength is sufficient, but release shock effects limit component life and testing capability
Solution Approach 1:
The system uses dynamically actuated cam levers that control the release of clamp elements in a controlled sequence. This dynamic mechanical release system reduces sudden shock effects compared to explosive separation, thereby extending component service life and enabling repeated testing without degradation from high-impact separation forces.
4Strength
If multiple bolts are used for fastening, then distributed load is achieved, but the number of parts and assembly complexity increases
Solution Approach 1:
The invention merges multiple discrete bolt fasteners into a unified clamp element system that distributes load around the circumference through continuous contact. This integration reduces the number of discrete parts and simplifies assembly while maintaining distributed load capability through the distributed clamp elements engaging with the flange surface.
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
The solution significantly reduces assembly and material costs, simplifies the manufacturing process, and enhances the reliability and testing capabilities of connector systems by eliminating explosive hazards and minimizing shock effects during separation.
Implementation Method 1
A non-explosive connector assembly utilizing a 3-D printed integral locking component with a central ring and leaf elements
Implementation Method 2
leaf elements that can be rotated to tension and release, reducing the number and cost of parts and simplifying assembly through additive manufacturing, allowing for repeated testing and deployment without shock
Data Source
AI summary
A spacecraft coupling system includes a locking component that can be deformed and placed into a stable state that locks one component into a mating component, and can easily be released from the deformed state, decoupling the two components. The locking component may include a central ring, a plurality of leaf elements arranged at the perimeter of the locking component, and a plurality of fins that extend outward from the ring to the plurality of leaf elements. A rotation of the ring element while the component is held stationary causes the fins to urge the leaf elements toward the receiving surface areas and to subsequently tension the leaf elements against surfaces on the mating component. To reduce cost and complexity, the locking component comprises a metal, such as titanium, that can be formed using an additive manufacturing process, commonly termed a 3-D printing process.