Satellite Coupling Interface With Capture Rollers for Reusable Docking
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Solution Overview
Problem
Existing satellite coupling systems are inadequate for repeated capture and release in space, particularly for low Earth orbit satellites, and do not facilitate electrical connections during repairs, limiting effective satellite servicing options.
Innovation Solution
A coupling system with a passive unit and an active unit, featuring a cam mechanism and capture rollers, allows for repeated capture and release, accommodating angular and linear misalignments, and includes an actuator for electrical connection through a central lead screw.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a single-use frangible joint is used to couple satellites to launch vehicles, then the connection is simple and reliable for launch, but it cannot be reused for in-orbit servicing and repairs
Solution Approach 1:
The coupling system transitions from a static frangible joint to a dynamic reusable mechanism. The cam-follower mechanism allows the capture rollers to move between engaged and disengaged positions, enabling repeated capture and release operations while maintaining reliable mechanical coupling during each mission phase.
Solution Approach 2:
The coupling system is divided into distinct functional components: an active unit with capture rollers and cam mechanism, and a passive unit with engagement features. This segmentation allows independent optimization of each component and enables the system to perform both launch attachment and in-orbit servicing functions.
2Ease of operation
If a robotic arm is used to capture satellites for repair, then capture is possible, but it cannot provide electrical connections between the repair vehicle and satellite
Solution Approach 1:
The coupling system merges mechanical capture functionality with electrical connection capabilities into a single integrated interface. The active unit combines capture rollers for mechanical engagement with electrical contacts that automatically connect when the passive unit is captured, enabling both capture and power/data transmission through one mechanism.
Solution Approach 2:
The coupling system serves multiple functions: mechanical capture during launch, electrical connection for power and data transmission, and support for in-orbit servicing operations. This multi-functionality eliminates the need for separate capture mechanisms and electrical connectors.
3Reliability
If satellites are replaced instead of repaired, then operational reliability is maintained, but the cost and time for replacement are extremely high
Solution Approach 1:
Instead of discarding malfunctioning satellites, the coupling system enables recovery and retrieval operations. The reusable capture mechanism allows servicing vehicles to grasp, transport, and return faulty satellites to Earth for repair, converting a disposable approach into a recoverable one that saves billions in replacement costs.
4Ease of repair
If the Space Shuttle is used for in-orbit repairs, then high-value satellites can be serviced, but the mission cost is extremely high and orbital access is limited
Solution Approach 1:
The coupling system enables automated or minimally-manned servicing operations, reducing dependence on expensive crewed missions. The self-contained mechanical and electrical interface allows unmanned servicing vehicles to perform capture, docking, and repair operations independently, dramatically reducing mission complexity and cost.
Data Source
AI summary
A coupling system and a method of coupling two objects. The coupling system including a passive unit having a first side and an opposing second side, the first side having a recess with a lip. The coupling system further having an active unit that includes an actuator, a cam mechanism and a plurality of capture rollers. The cam mechanism is operably coupled to the actuator, the cam mechanism being movable from a stowed position to a deployed position. The plurality of capture rollers is operably coupled to the cam mechanism to move from a first position to a second position in response to the cam mechanism moving from the stowed position to the deployed position, the plurality of capture rollers engaging the lip in the second position when the passive unit is in contact with the active unit.