In-Space Assembly of High-Strength Composite Booms
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Solution Overview
Problem
Transporting large, assembled structures into space is impractical, costly, and often impossible, necessitating in-space assembly of components like struts for larger structures.
Innovation Solution
The method involves using a robotic arm with a printhead to assemble high-strength composite (HSC) booms in space. The process includes spooling the HSC boom, positioning the robotic arm, dispensing lengths of the boom, and joining them using mechanical fasteners or fusion methods.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If large assembled structures are transported into space, then the structure can be immediately used, but transportation becomes impractical, costly, and often impossible
Solution Approach 1:
The structure is divided into compact, stowable components that can be transported separately and assembled in space. The robotic system enables assembly of truss structures from segmented booms and struts that are stored in a compact configuration during launch and then deployed and assembled in orbit.
Solution Approach 2:
The booms and structural components are designed to nest within each other during stowed configuration, similar to nested dolls. The booms can be collapsed and stored within a limited volume, allowing large structures to be transported in compact form factors that fit within rocket fairings and spacecraft cargo areas.
2Adaptability or versatility
If in-space assembly is performed, then transportation limitations are overcome, but assembly complexity and automation requirements increase
Solution Approach 1:
The robotic arm system is designed with universal end effectors and printheads that can perform multiple functions including gripping, positioning, and joining different types of structural components. The system can assemble various configurations of booms, struts, and connectors using the same basic robotic platform, reducing overall system complexity while maintaining versatility.
Solution Approach 2:
The assembly system incorporates self-aligning features and automated joining mechanisms that reduce the complexity of precise positioning and alignment. The mechanical fastening systems and fusion joining processes are designed to automatically align components during assembly, reducing the burden on robotic positioning precision and simplifying control requirements.
3Ease of operation
If mechanical fastening is used to join booms, then assembly is simplified and automated, but joint strength and structural integrity may be compromised
Solution Approach 1:
The system uses high-strength composite materials for the booms and struts that are designed to work with mechanical fastening systems. The composite materials provide high strength-to-weight ratios that compensate for the presence of mechanical joints, maintaining overall structural integrity while enabling automated assembly. The fasteners are designed to optimize load distribution through the composite material cross-sections.
Data Source
AI summary
A method of in-space assembly includes: providing a roll of spooled high strength composite (HSC) boom, a robotic arm, and a printhead disposed at about an end of the robotic arm, the roll of spooled high strength composite boom feedingly coupled to the printhead; positioning the robotic arm; dispensing from the roll of spooled high strength composite boom a length of high strength composite boom; positioning again the robotic arm; dispensing another length of high strength composite boom from the roll of spooled high strength composite boom or from another roll of spooled high strength composite boom; joining by the printhead; and repeating said step of positioning to said step of joining until a desired structure is assembled in part or in whole. A system for in-space assembly and printhead to print struts for in-space assembly are also described.