Spacecraft Coupling Unit Gas Generator Separation
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Solution Overview
Problem
Pyrotechnic fasteners used in spacecraft coupling units can cause shock and fail to provide adequate distance between decoupled parts, leading to potential damage and requiring separate thruster activation, which is inefficient and poses risks to sensitive structures.
Innovation Solution
A coupling unit with a first element fixedly connected to one part and a second element with a gas generator that generates high pressure to break breakable fixation elements, allowing the first element to be pushed out and creating distance between the parts, providing a compact, reliable, and safe connection and disconnection mechanism.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If pyrotechnic fasteners are used for coupling spacecraft parts, then the connection strength during launch is improved, but shock and high loads are generated that may harm sensitive structures
Solution Approach 1:
The coupling device is divided into two separate functional elements: a mechanical coupling element that provides connection strength during launch, and a separate gas generator that provides the breaking force. This segmentation allows each element to be optimized independently - the coupling element can be designed for maximum strength without considering the breaking mechanism, while the gas generator can be designed to provide controlled force without creating harmful shocks.
Solution Approach 2:
A piston is introduced as an intermediary between the gas generator and the coupling elements. The gas generator produces gas that acts on the piston, which then transfers the force to break the fixation elements. This intermediary smooths out the force transmission, converting the potentially shock-inducing gas expansion into a more controlled breaking action that reduces harmful loads on sensitive structures.
2Device complexity
If pyrotechnic fasteners are used alone, then the structure is simplified, but adequate distance between decoupled parts is not provided
Solution Approach 1:
The invention merges two previously separate functions into a single integrated coupling device: the mechanical coupling function and the separation function. The gas generator is incorporated directly into the coupling device structure, eliminating the need for separate thrusters while ensuring adequate distance is provided between decoupled parts. This combination maintains structural simplicity while achieving the distancing function.
3Length of moving object
If separate thruster is added to pyrotechnic fastener to provide distancing, then distance between decoupled parts is improved, but device complexity and activation requirements increase
Solution Approach 1:
The gas generator is integrated directly into the coupling device structure, merging the separation function with the coupling function. This eliminates the need for separate thrusters and reduces the number of activation requirements to a single initiation event. The piston mechanism serves as a force multiplier, allowing a compact gas generator to produce sufficient breaking force while maintaining a simple overall structure.
4Weight of moving object
If separate thruster is mounted on the lighter part, then weight distribution is optimized, but exhaust gases are directed toward the more important part causing potential damage
Solution Approach 1:
The harmful exhaust gases are extracted and contained within the coupling device structure itself, rather than being expelled toward other spacecraft components. The gas generator is positioned and oriented so that exhaust is directed away from sensitive structures, and the piston mechanism channels the gas pressure through the fixation elements to achieve breaking without exposing other parts to hot exhaust.
5Reliability
If pyrotechnic fastener and separate thruster are combined, then decoupling function is improved, but two activations are required reducing operational efficiency
Solution Approach 1:
The coupling and separation functions are merged into a single integrated device that responds to a single activation event. The gas generator is triggered by the same signal that initiates separation, eliminating the need for a second activation. The piston mechanism automatically translates the gas pressure into breaking force, providing a reliable one-step decoupling process that reduces operational time and complexity.
Data Source
AI summary
A coupling unit is disclosed for detachable coupling two pars of a spacecraft, the coupling unit connecting the two parts of the spacecraft in a connected condition and the coupling unit distancing the two parts of the spacecraft, when the coupling unit is in detached condition. The coupling unit comprises a first element and a second element engaged to each other in connected condition, with the second element comprising a gas generator for generating gas under pressure to detach the first and the second element to bring them in the detached position, thereby distancing the first element and the second element from each other, and thus also the first part and the second part connected to the respective elements.