Robotic Brazing of Space Frame Truss Nodes
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Solution Overview
Problem
Current space frame structures require complex and labor-intensive assembly processes, making them expensive and difficult to manufacture, especially for applications in space where robotic assembly methods are lacking, and traditional welding techniques lead to thermal distortion and misalignment issues.
Innovation Solution
A strut-and-node truss design that allows for robotic assembly and joining using brazing or deposition methods, employing ball spring plungers for precise positioning and reduced heat input, enabling efficient and precise assembly of truss structures in space with minimal human interaction.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If traditional fusion welding processes are used to join space frame structures, then strong joints can be achieved, but thermal distortion and misalignment occur due to high heat input
Solution Approach 1:
The patent changes the thermal parameters of the joining process by using brazing instead of fusion welding, operating at lower temperatures (below the melting point of the base metals) to achieve joint strength while minimizing thermal distortion and misalignment of the space frame structure
Solution Approach 2:
The patent replaces the high-heat fusion welding process with a brazing process that uses a filler metal and controlled heat application, substituting the aggressive thermal-mechanical system with a more controlled thermal-chemical system that preserves dimensional accuracy
2Productivity
If robotic assembly methods are implemented for space frame structures, then assembly efficiency can be improved, but precise positioning and control are challenging due to complex joint geometries
Solution Approach 1:
The patent designs self-aligning joint features including tapered bore geometries and spherical interfaces that automatically guide and position components during robotic assembly, allowing the structure itself to facilitate precise positioning without complex robotic control systems
Solution Approach 2:
The patent incorporates pre-configured alignment features and pre-positioned bonding surfaces on components before assembly, enabling robotic systems to simply execute the joining operation without requiring complex real-time positioning and control algorithms
3Ease of manufacture
If manual assembly processes are used for space frame structures, then complex joints can be assembled with human skill, but labor intensity and cost increase significantly
Solution Approach 1:
The patent divides the space frame structure into modular components with standardized joint interfaces, allowing complex structures to be assembled from simpler, pre-fabricated segments that can be joined using straightforward robotic operations rather than complex manual procedures
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
This approach enables the construction of precise truss structures with reduced thermal distortion and misalignment, facilitating efficient assembly of space-based structures like antennas and telescopes, while minimizing power consumption and robotic arm articulation.
Implementation Method 1
a node member engagement element biased to protrude into the channel
Implementation Method 2
ball spring plungers for precise positioning
Implementation Method 3
employing ball spring plungers for precise positioning and reduced heat input, enabling efficient and precise assembly of truss structures in space
Implementation Method 4
employing ball spring plungers for precise positioning and reduced heat input, enabling efficient and precise assembly of truss structures in space
Data Source
AI summary
A strut-and-node truss design that is applicable to all space frame structure designs can be made with using robotic (semi-autonomous and/or fully autonomous) or telerobotic assembly/joining. Nodes can include a 2-dimensional weld path in an effort to reduce the complexity of having to weld in 3-dimensions. Furthermore, each strut to node connection can be concentrated in a small area where each weld can be performed robotically from a fixed position that only requires the robotic weld head to swivel in a small operating window to reach each joint.