Spacecraft Material Transfer Coupler for Misalignment-Tolerant Refueling
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Solution Overview
Problem
Existing space systems face limitations in refueling spacecraft due to complex and incompatible docking systems, which restrict the longevity and utility of space missions, as well as the ability to transfer materials like fuel and waste.
Innovation Solution
A system comprising a first coupler with rotatable and translatable latch arms and a valve device on one spacecraft, and a second coupler with a corresponding valve device on another, allowing for autonomous or semi-autonomous material transfer, including fuel, through a mechanism that can align and seal properly, store energy for separation, and handle minor misalignments.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If existing docking systems are used for spacecraft refueling, then docking capability is provided, but the systems are complicated and have compatibility issues between different satellites
Solution Approach 1:
The docking interface is designed with universal features that allow different spacecraft to interoperate. The standardized mechanical interface and electrical connectors enable compatibility across multiple satellite platforms while maintaining a relatively simple structure. The valve assembly design allows the same basic mechanism to work with different propellant types and spacecraft configurations.
Solution Approach 2:
The docking system is divided into separate functional modules: mechanical coupling components, electrical connector components, and valve assembly components. This segmentation allows each subsystem to be optimized independently and facilitates maintenance and replacement without affecting the entire docking system.
2Duration of action of moving object
If spacecraft are launched with full fuel capacity, then fuel availability for entire lifetime is ensured, but payload capacity and mission flexibility are limited
Solution Approach 1:
Fuel resupply capability is established before the spacecraft needs it by enabling docking with refueling vehicles. The spacecraft can be launched with minimal fuel and subsequently refueled during its operational lifetime, eliminating the need to carry full fuel capacity from launch while ensuring fuel availability when needed.
Solution Approach 2:
The system enables recovery of fuel resources by allowing transfer of propellant from refueling vehicles to operational spacecraft. This recovers the value of fuel that would otherwise be wasted in single-use or limited-life missions, extending spacecraft operational lifetime without requiring excessive initial fuel loading.
3Ease of operation
If existing docking systems are used, then docking capability is provided, but material transfer interfaces are inadequate
Solution Approach 1:
The mechanical docking interface and material transfer interface are merged into a single integrated assembly. The valve mechanism is incorporated within the docking interface structure, allowing both mechanical coupling and propellant transfer to occur through the same physical connection point, eliminating the need for separate docking and fueling operations.
Solution Approach 2:
The valve assembly acts as an intermediary component between the docking mechanical interface and the propellant storage systems. It mediates the connection between two spacecraft, controlling the flow of material while being actuated through the docking interface itself, thereby simplifying the overall system architecture.
4Productivity
If autonomous docking is implemented, then operational efficiency is improved, but control and alignment precision become more difficult
Solution Approach 1:
The docking interface incorporates spherical or curved alignment features that provide mechanical guidance during the autonomous docking process. These geometric features naturally guide the approaching spacecraft into proper alignment, reducing the precision requirements for active control systems while enabling autonomous operation.
Solution Approach 2:
The docking system includes self-aligning and self-latching features that automatically adjust and secure the connection without requiring precise external control. The mechanical design provides inherent guidance and correction capabilities, allowing the system to self-correct minor misalignments during autonomous approach and docking.
Data Source
AI summary
Material transfer interfaces for space vehicles, and associated systems and methods are disclosed. A representative system includes a first coupler configured to be carried by a first space vehicle, and a first valve device carried by the first coupler. The system further includes a second coupler configured to be carried by a second space vehicle and a second valve device carried by the second coupler. The first coupler includes rotatable and translatable latch arms positioned to engage with and connect to the second coupler. The first valve device incudes a moveable probe that is insertable into the second valve device when the latch arms of the first coupler are connected to the second coupler to transfer fluid between the first and second valve devices.