Solar On-Orbit Welding with Adjustable Beam Control
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Solution Overview
Problem
Current in-space welding technologies face challenges with high electrical power requirements, excessive launch resources, and limited material and thickness applicability, making them unsuitable for efficient welding and joining of large structures in space.
Innovation Solution
A solar-thermal welding system (SO-WARM) using concentrated solar energy with optical and weld control components, including a primary solar concentrator, redirecting mirrors, robotic end effector, weld control subsystems, and sensors for precise temperature and heat control, enabling welding of metals and non-metals with reduced electrical power demands.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Use of energy by moving object
If conventional electron beam welding systems are used in space, then welding capability is achieved, but electrical power consumption increases significantly
Solution Approach 1:
The patent replaces the electron beam welding system (electrical/mechanical) with a solar concentrator system (optical/thermal). The solar concentrator focuses sunlight directly onto the weld zone, eliminating the need for high-power electrical systems while maintaining welding capability through thermal energy concentration.
Solution Approach 2:
The system utilizes solar energy from space environment itself as the power source. By harnessing the abundant sunlight available in space, the system serves its own energy needs without requiring external electrical power supply, thereby reducing electrical power consumption while maintaining reliable welding operation.
2Reliability
If heavy welding equipment is launched to space, then welding function is provided, but launch mass increases excessively
Solution Approach 1:
The patent replaces heavy electrical welding equipment with a lighter optical system. The solar concentrator uses mirrors and optical components that are significantly lighter than electron beam generators or arc welding equipment, reducing launch mass while providing the same welding function through optical concentration rather than electrical power.
Solution Approach 2:
The system extracts and utilizes the welding capability from the solar energy source itself rather than bringing heavy welding equipment. By taking out the energy source (sunlight) and concentrating it optically, the system provides welding function without the mass penalty of traditional welding equipment.
3Adaptability or versatility
If traditional welding methods are used in space, then joining capability is achieved, but applicability to various materials and thicknesses is limited
Solution Approach 1:
The solar concentrator system allows dynamic adjustment of concentration parameters including spot size, energy density, and focal position. By changing these optical parameters, the system can adapt to different material types and thicknesses while maintaining reliable joining capability, unlike fixed-parameter traditional welding methods.
Solution Approach 2:
The optical concentration mechanism provides universal applicability across different materials and thicknesses. The same solar concentrator system can weld various materials (metals, polymers, ceramics) and different thicknesses by adjusting optical parameters, making it a multi-functional system that surpasses the limited material applicability of traditional welding methods.
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 system achieves precise welding and joining of various materials in space with reduced power requirements, allowing for the assembly, repair, and disassembly of large structures, and reduces launch mass and cost by leveraging solar energy directly for fusion joining.
Implementation Method 1
a primary solar concentrator configured to receive solar energy and provide concentrated solar energy (CSE)
Implementation Method 2
receive solar energy and provide concentrated solar energy (CSE)
Implementation Method 3
the focal distance actuator receives the CSE and provides a first energy beam of a selectable energy density
Implementation Method 4
the iris shutter receives the first energy beam and provides the welding energy beam having a selectable spot size
Implementation Method 5
the welding energy beam passes into an interior of the weld reflector and engages with the weld material at the welding site to create an irradiation zone that forms a weld on the work piece
Implementation Method 6
the weld reflector at least partially encloses the irradiation zone to reduce energy losses of the irradiation zone, the energy losses comprising at least one of radiation energy losses and reflection energy losses
Implementation Method 7
the weld reflector at least partially encloses the irradiation zone to reduce energy losses of the irradiation zone, the energy losses comprising at least one of radiation energy losses and reflection energy losses
Data Source
AI summary
A welding system and method of use, in particular a welding system that performs welding in the vacuum environment of space using concentrated solar energy. The system produces concentrated solar energy through a set of optical elements. A set of weld control elements including a focal distance actuator, an iris shutter, and a weld reflector produce a welding energy beam from the concentrated solar energy, the welding energy beam of selectable energy density and spot size and directed at an irradiation zone of a work piece wherein a weld is formed. A work piece end effector positions the work piece relative to the irradiation zone.