Spacecraft Exoskeleton Truss Structure for Mass Reduction
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Solution Overview
Problem
Conventional spacecraft structural support systems face challenges in sustaining large loads during launch, managing temperature excursions, and maintaining precise component alignment while efficiently dissipating heat and optimizing payload electronics placement.
Innovation Solution
The implementation of a 3-D exoskeleton truss structure that mechanically couples internal equipment panels and external radiator panels with a structural interface adapter, using carbon composite materials and heat pipes for thermal coupling, and ring clamps for modular assembly, providing a thermally stable and mass-efficient framework for load distribution and alignment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If conventional structural support systems are used, then the spacecraft can be assembled, but the structural integrity and mass efficiency are insufficient
Solution Approach 1:
The patent employs carbon fiber reinforced polymer (CFRP) composite materials for the truss structure members, combining high strength-to-weight ratio requirements. The composite material provides both structural integrity and mass efficiency by offering superior strength while reducing the overall mass of the sidewall structure compared to conventional materials.
Solution Approach 2:
The structural support system is segmented into modular truss structures with interconnected nodes and members. This segmentation allows for optimized load distribution across discrete structural elements, improving overall structural integrity while enabling mass reduction through efficient material placement only where structurally necessary.
2Temperature
If equipment panels and radiator panels are mechanically coupled, then thermal management is achieved, but thermal stability during temperature excursions is challenging
Solution Approach 1:
The thermal management system is segmented into separate equipment panels and radiator panels connected through the truss structure. This segmentation allows independent thermal zones that can be optimized for their specific thermal requirements while maintaining structural connectivity, enabling effective heat dissipation while managing thermal expansion differences.
Solution Approach 2:
The patent incorporates thermal expansion compensation mechanisms that allow structural parameters to change with temperature. The truss structure and panel connections are designed to accommodate thermal excursions through controlled parameter changes, maintaining thermal stability despite large temperature variations during spacecraft operation.
3Temperature
If payload electronics are placed on radiator panels, then heat dissipation is improved, but precise alignment of components is difficult to maintain
Solution Approach 1:
Payload electronics are placed on separate equipment panels rather than directly on radiator panels. This segmentation allows independent optimization of each panel's function - radiator panels for heat dissipation and equipment panels for precise component mounting. The truss structure provides stable mechanical coupling between panels, maintaining alignment precision while enabling effective thermal management.
4Ease of manufacture
If modular assembly with ring clamps is used, then ease of integration and testing is improved, but structural complexity increases
Solution Approach 1:
The spacecraft structure is divided into modular segments that can be independently assembled and tested using ring clamps. This segmentation improves ease of manufacture by allowing parallel assembly of separate modules and simplified integration. The modular design with standardized connection interfaces manages structural complexity through repetition of proven connection designs rather than requiring complex custom solutions.
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 enhances the structural integrity and thermal management of spacecraft, reduces mass on sidewalls, optimizes payload placement, and improves payload efficiency by reducing waveguide line losses and increasing modularity for easier integration and testing.
Implementation Method 1
The at least one equipment panel and the at least one radiator panel is coupled mechanically by one or both of the first 3-D truss structure and the second 3-D truss structure with the structural interface adapter
Data Source
AI summary
A spacecraft includes a structural interface adapter for mating to a launch vehicle, at least one radiator panel, at least one equipment panel, a first 3-D truss structure proximal to and mechanically coupled with the structural interface adapter, and a second 3-D truss structure distal from the structural interface adapter and coupled mechanically with the structural interface adapter by way of the first 3-D truss structure. The at least one equipment panel and the at least one exterior radiator panel is coupled mechanically by one or both of the first 3-D truss structure and the second 3-D truss structure with the structural interface adapter. Each 3-D truss structure includes at least four coupling nodes and at least six strut elements, attached together by a respective plurality of joints, each strut element disposed between and attached with a respective pair of the plurality of coupling nodes.