Spacecraft Bolt Release Mechanism for Low-Shock Separation

Resolve Bottlenecks,
Find Innovative SolutionsGenerate Solutions

Solution Overview

Problem

Existing spacecraft and launcher separation systems using pyrotechnic bolts generate high vibratory disturbances and shocks, produce debris, and are not easily refurbishable, requiring costly redesigns and long qualification processes.

Innovation Solution

A bolt release system comprising a release device, a bolt, first and second retaining means, and elastic means, with complementary surfaces and retaining caps, allowing for mechanical and electrical interchangeability, lower shock generation, and debris-free operation.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If pyrotechnic bolts are used for spacecraft separation, then effective and reliable connection is achieved, but high levels of vibratory disturbance and shocks are generated

Engineering Contradiction:

Improveconnection reliabilityVSAvoidvibratory disturbance

Core Design Contradiction:

ReliabilityVSObject-affected harmful factors

Solution Approach 1:

The patent replaces the pyrotechnic (chemical) cutting mechanism with a mechanical release system. The bolt is retained by retaining means (such as clips or latches) that can be mechanically actuated to release the bolt without combustion. This substitution eliminates the high-temperature combustion process that generates vibratory disturbances and shocks, while maintaining reliable connection during the attached phase and clean separation during release.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

2Ease of operation

If pyrotechnic cutters are used to cut the bolt, then separation is achieved, but debris is produced and high shock is generated

Engineering Contradiction:

Improveseparation capabilityVSAvoiddebris

Core Design Contradiction:

Ease of operationVSObject-generated harmful factors

Solution Approach 1:

The patent replaces the pyrotechnic cutter (chemical cutting process) with a mechanical release mechanism. The retaining means (clips, latches, or other mechanical retainers) hold the bolt in place and can be mechanically actuated to release it. This mechanical approach avoids the combustion and material fragmentation associated with pyrotechnic cutters, thereby eliminating debris generation and reducing shock while maintaining effective separation capability.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

3Reliability

If pyrotechnic bolts are used for separation, then effective connection is maintained, but the system is not refurbishable and requires costly redesign

Engineering Contradiction:

Improvejoining effectivenessVSAvoidrefurbishment capability

Core Design Contradiction:

ReliabilityVSEase of repair

Solution Approach 1:

The patent designs the bolt and retaining means as reusable components. After separation, the bolt can be recovered and refurbished for future use, unlike pyrotechnic bolts that are consumed and require replacement. The mechanical retaining means can also be inspected, maintained, and reused. This recoverability enables refurbishment programs, reducing costs and avoiding the need for costly redesigns and lengthy qualification processes associated with disposable pyrotechnic systems.

Inventive Principle:

Principle #34Discarding and recovering

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 reduces shock and debris generation, enables refurbishment, and allows for cost-effective use of interchangeable components, reducing dependence on high-performance pyro-cutters.

Implementation Method 1

a first elastic means configured to act on the first retaining means, a second elastic means configured to act on the second retaining means

Methodology Applied

Scientific EffectElasticity: Elasticity

Implementation Method 2

at least an energy storing means devised to convert, during separation, at least part of the prestress-stored strain energy to rotational energy

Methodology Applied

Scientific EffectStrain energy conversion: Spring

Data Source

PatentEP4559819B1Bolt release system for spacecraft and launcher separation systems and separation system comprising same

Publication Date: 2026.01.14 AIRBUS DEFENCE & SPACE SAU

Figure 1
Figure 2~3
Figure 4~5

AI summary

Bolt release system for spacecraft and launcher separation systems, that comprises a release device (1), a bolt (2) connected to the release device (1) and protruding from it, first retaining means (3), with at least one end surface (4) and an inner hole and first elastic means, second retaining means (5), with at least one end surface (6) and an inner hole and second elastic means, a first retaining cap (13) configured to retain the first retaining means (3) in an open position of the bolt release system, a second retaining cap (14) configured to retain the second retaining means (5) in an open position of the bolt release system, a releasing bolt (9), comprising an end section (10) with opposed surfaces (11) and a transversal cut (12) in its most extreme position between the opposed surfaces (11), such that the opposed surfaces (11) are complementary to at least one end surface (4) of the first retaining means (3) and to at least one end surface (6) of the second retaining means (5), such that the corresponding complementary surfaces are configured to be able to fit with each other as mating surfaces, and in a closed position of the bolt release system the end section (10) is coupled and retained between one end surface (4) of the first retaining means (3) and one end surface (6) of the second retaining means (5), and the bolt (2) connected to the release device (1) crosses the inner hole of the first retaining means (3), the end section (10) and the inner hole of the second retaining means (5).