Satellite Refueling Quick Disconnect With Redundant Hypergolic Seals
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Solution Overview
Problem
Satellites often deplete propellant, leading to decommissioning and de-orbiting due to lack of onboard propellant, which prevents proper attitude and navigational control, and existing technologies struggle with refueling non-cooperative satellites with hypergolic propellants that are corrosive and react with materials, causing ignition and integrity issues.
Innovation Solution
A universal quick disconnect (QD) apparatus and refueling tool system that allows tele-operated robotic refueling of satellites by converting non-cooperative satellite fill and drain valves into cooperative interfaces, using a robot arm to attach and detach the QD apparatus, which includes a hex drive and split threads to prevent cross-threading and provides redundant seals for hypergolic propellant handling.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If existing refueling technologies are used on non-cooperative satellites, then refueling operations can be performed, but the corrosive hypergolic propellants cause material degradation and ignition issues
Solution Approach 1:
The patent introduces a quick disconnect apparatus as an intermediary component between the refueling system and the satellite fill and drain valve. This apparatus includes a poppet fitting subassembly with seals and a body that interfaces with the satellite valve, acting as a protective mediator that prevents direct contact between corrosive hypergolic propellants and satellite materials while enabling safe fuel transfer operations
Solution Approach 2:
The quick disconnect apparatus incorporates redundant sealing mechanisms (poppet seal, O-ring seals) and a structured body design that provides protective barriers before propellant contact. These pre-positioned sealing elements cushion against potential leakage and material degradation by creating multiple protective layers that prevent harmful propellant-satellite material interactions
2Adaptability or versatility
If a universal connector is designed to work with various satellite geometries, then compatibility is improved, but device complexity increases
Solution Approach 1:
The quick disconnect apparatus is designed as a universal connector that can interface with various satellite fill and drain valve geometries. The poppet fitting subassembly and body structure are configured to accommodate different valve configurations through a standardized interface design, enabling a single apparatus to perform multiple satellite refueling operations across different geometries without requiring geometry-specific custom connectors
Solution Approach 2:
The connector is divided into distinct functional segments: a body portion that provides the interface structure, a poppet fitting subassembly that contains sealing elements, and a quick disconnect mechanism. This segmentation allows each component to be optimized for its specific function while maintaining overall universality, reducing the complexity that would arise from designing a monolithic universal connector
3Ease of operation
If manual refueling operations are performed, then flexibility is maintained, but operation time and human exposure to hazardous propellants increase
Solution Approach 1:
The quick disconnect apparatus incorporates a quick disconnect mechanism that enables automated or tele-operated attachment and detachment from satellite fill and drain valves. This self-service capability allows the refueling system to perform connection and disconnection operations autonomously or under remote control, eliminating the need for prolonged manual operations and reducing human exposure time to hazardous hypergolic propellants while maintaining operational flexibility through programmable control
Data Source
AI summary
A quick disconnect apparatus including a first end configured to interface with a legacy fill and drain valve (FDV) of a satellite to be serviced, a second end configured to interface with a refueling tool, and a middle portion including at least one redundant seal to prevent unwanted fuel transfer during connection of the FDV and refueling tool.