Space Optical Sensor Mounting Structure Thermal Isolation
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Solution Overview
Problem
Traditional space-based optical system designs that directly mount inertial rate sensors and star tracker sensors to the primary support structure face integration, thermal, and packaging challenges, leading to increased costs and lengthy design processes, as well as serial configuration requirements and heat management complications.
Innovation Solution
An integrated mount for star tracker sensors and inertial rate sensors attached directly to the metering structure, using a thermally and mechanically stable, non-zero CTE material with flexures and thermal isolators to accommodate thermal expansion and maintain pointing accuracy, allowing for parallel design of these components with the optical system.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If inertial rate sensor and star tracker sensors are directly mounted to the primary support structure, then pointing accuracy is improved, but device complexity and integration difficulty increase
Solution Approach 1:
The patent divides the sensor mounting system into separate modular components: a sensor mount assembly that holds both sensors, a flexure mechanism for thermal accommodation, and a thermal isolator between the sensor assembly and primary support structure. This segmentation reduces integration complexity by allowing independent design and assembly of each component while maintaining the required pointing accuracy through precise mechanical interfaces.
Solution Approach 2:
The patent introduces a flexure mechanism as an intermediary element between the sensor mount and the primary support structure. This flexure assembly acts as a mediator that decouples the rigid mounting requirement from the thermal expansion reality, allowing the sensors to maintain their precise positions while accommodating thermal movements through controlled elastic deformation.
2Stability of the object's composition
If low CTE materials are used to mount sensors, then pointing stability is improved, but manufacturing cost and complexity increase
Solution Approach 1:
The patent changes the material parameter approach by using standard CTE materials (aluminum or stainless steel) instead of specialized low CTE materials. The flexure mechanism is designed to compensate for the higher CTE through its elastic properties, allowing the system to achieve thermal stability without relying on expensive and difficult-to-manufacture low CTE materials.
Solution Approach 2:
The patent employs a composite approach combining different materials with complementary properties: the sensor mount uses aluminum for lightweight construction, the flexure uses elastomeric or polymeric materials for thermal compliance, and the thermal isolator uses materials with low thermal conductivity. This composite material strategy achieves thermal stability while maintaining ease of manufacture.
3Adaptability or versatility
If star tracker sensors are extended up and out from metering structure, then view to space is maintained, but thermal management difficulty increases
Solution Approach 1:
The patent extracts the thermal management function from the structural mounting system by introducing a dedicated thermal isolator component. This isolator is positioned between the sensor assembly and the primary support structure to block thermal conduction paths, allowing the sensors to be extended away from the metering structure for proper viewing while managing thermal effects independently.
Solution Approach 2:
The thermal isolator serves as a thermal intermediary element that breaks the thermal conduction path between the warm primary support structure and the sensors. This allows the sensors to be positioned optimally for viewing while the isolator manages the thermal isolation requirements.
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
This solution reduces design complexity and time, manages thermal issues effectively, and maintains pointing accuracy by isolating sensors from the optical system, enabling efficient thermal management and parallel design processes.
Implementation Method 1
using a thermally and mechanically stable, non-zero CTE material with flexures and thermal isolators to accommodate thermal expansion
Implementation Method 2
using a thermally and mechanically stable, non-zero CTE material with flexures and thermal isolators to accommodate thermal expansion
Implementation Method 3
using a thermally and mechanically stable, non-zero CTE material with flexures and thermal isolators to accommodate thermal expansion
Data Source
AI summary
A space optical system is disclosed. The space optical system can include a primary support structure in support of a primary mirror. The space optical system can also include a sensor mounting structure coupled to the primary support structure and extending to an exterior of space optical system. The space optical system can further include first and second sensors mounted on the sensor mounting structure. In one aspect, the sensor mounting structure can comprise a thermally and mechanically stable, non-zero CTE material.