Robotic Space Frame Assembly Using Modular Strut-and-Node Design

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Solution Overview

Problem

Current space frame structures require complex and costly human labor for assembly, especially in space, due to intricate assembly steps and the need for skilled welders, which limits efficient construction and deployment of large structures like satellites and spacecraft.

Innovation Solution

A robotic assembly system using a strut-and-node design that enables semi-autonomous or fully autonomous assembly and joining, employing brazing or deposition technologies to minimize thermal distortion and power consumption, allowing for precise assembly of truss structures in space.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If traditional mechanical fasteners and fusion welding processes are used for space frame assembly, then structural strength and reliability are improved, but assembly complexity and human skill requirements increase significantly

Engineering Contradiction:

Improvestructural reliabilityVSAvoidassembly complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The space frame structure is divided into modular components (nodes and struts) that can be assembled in a systematic sequence. Each node serves as a standardized connection point for multiple struts, breaking down the complex welding task into repeatable, manageable units that reduce overall assembly complexity while maintaining structural integrity

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

Struts are pre-positioned and mechanically fastened to nodes before final welding occurs. This preliminary mechanical assembly establishes precise geometric relationships and alignment, making the subsequent welding process simpler and more reliable by eliminating the need for complex fit-up procedures during welding

Inventive Principle:

Principle #10Preliminary action

2Strength

If full circumferential welds are performed on difficult pipe joints, then joint strength is improved, but assembly time and skill requirements increase due to difficult fit up and positioning

Engineering Contradiction:

Improvejoint strengthVSAvoidassembly time

Core Design Contradiction:

StrengthVSLoss of time

Solution Approach 1:

Nodes and struts are pre-assembled with mechanical fasteners to establish precise alignment and positioning before welding begins. This preliminary mechanical connection ensures that when welding occurs, the components are already in their final positions, eliminating time-consuming fit-up and positioning operations during the welding process

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

Traditional complex mechanical fit-up procedures are replaced with a standardized node-and-strut system using mechanical fasteners. This standardized mechanical connection system provides inherent alignment features that simplify the welding process by eliminating the need for complex measurement and adjustment procedures

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

3Productivity

If robotic assembly is implemented for space frame construction, then productivity and precision are improved, but system complexity and initial cost increase

Engineering Contradiction:

Improveassembly productivityVSAvoidsystem complexity

Core Design Contradiction:

ProductivityVSDevice complexity

Solution Approach 1:

The robotic assembly system operates on modular nodes and struts with standardized connection interfaces. This segmentation allows the robot to perform repeatable pick-and-place operations using simple grippers, reducing the complexity of the robotic system while maintaining high productivity through automation of the assembly process

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

Complex manual welding and positioning operations are replaced with a simplified robotic system that uses mechanical fasteners for preliminary assembly. The robot performs straightforward tasks of positioning and fastening components, which are then followed by simpler welding operations, overall reducing system complexity while increasing productivity

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

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

Enables efficient and precise assembly of space frame structures in space with reduced human intervention, improving volumetric packing efficiency during launch and enabling the construction of complex structures like antennas and habitats with minimal distortion and high precision.

Implementation Method 1

employing brazing or deposition technologies to minimize thermal distortion and power consumption

Methodology Applied

Scientific EffectBrazing: Brazing

Implementation Method 2

employing brazing or deposition technologies to minimize thermal distortion and power consumption

Methodology Applied

Scientific EffectDeposition: Deposition (physical)

Data Source

PatentUS11358738B1Systems and methods for assembling space frame structures

Publication Date: 2022.06.14 LOCKHEED MARTIN CORP

AI summary

A strut-and-node truss design that is applicable to space frame structure designs can be assembled with using robotic (semi-autonomous and/or fully autonomous) or telerobotic assembly/joining. The assembly system can include a storage module that includes the components for assembly and an assembly module that can retrieve and assembly the components. The resulting truss structure can be connected to an antenna (e.g., carried by the storage module) for deployment. The assembly module can be operated repeatedly in conjunction with additional resupply systems that provide additional components for assembly.