Modular UUV Connectors With Magnets for Tool-Free Repair

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Solution Overview

Problem

Unmanned underwater vehicles (UUVs) are expensive to produce and operate due to their specialized design, limited market, proprietary systems, and inability to adapt to changing mission requirements, leading to high operator costs and mission risks.

Innovation Solution

Implement additively manufactured connectors and ball bearings for modular components, including optical communication modules, allowing quick and reliable attachment/detachment of components without tools, and using magnets and ball bearings to minimize hull penetrations, enabling reconfiguration and repair in the field.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If specialized designs are used for specific missions, then mission performance is improved, but production cost and operator cost increase

Engineering Contradiction:

Improvemission performanceVSAvoidproduction cost

Core Design Contradiction:

ReliabilityVSEase of manufacture

Solution Approach 1:

The vehicle system is divided into modular components that can be independently manufactured and assembled. Different mission-specific modules (propulsion, sensors, payloads) can be attached to a common platform, allowing specialized performance without custom manufacturing of entire vehicles. This reduces nonrecurring engineering costs while maintaining mission effectiveness.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

A common vehicle platform is designed with universal attachment interfaces that can accommodate multiple types of mission modules. The same base vehicle can be reconfigured for different missions by swapping modules, eliminating the need to manufacture separate specialized vehicles for each mission type, thereby reducing production costs.

Inventive Principle:

Principle #6Universality (Multi-functionality)

2Manufacturing precision

If fixed vehicle designs are manufactured, then manufacturing precision is improved, but adaptability to changing mission requirements deteriorates

Engineering Contradiction:

Improvedesign consistencyVSAvoidmission flexibility

Core Design Contradiction:

Manufacturing precisionVSAdaptability or versatility

Solution Approach 1:

The vehicle system transitions from a static fixed design to a dynamic reconfigurable system. Modular components with standardized interfaces allow the vehicle to be reconfigured in the field for different missions, maintaining manufacturing precision for each module while achieving overall system adaptability through combinatorial configurations.

Inventive Principle:

Principle #15Dynamics

3Reliability

If proprietary systems are implemented, then reliability for specific missions is improved, but ease of repair and component sharing deteriorates

Engineering Contradiction:

Improvesystem performanceVSAvoidfield repairability

Core Design Contradiction:

ReliabilityVSEase of repair

Solution Approach 1:

Standardized mechanical and electrical interfaces are implemented across all modules, allowing components from different vehicles to be interchanged and repaired in the field. This universal interface approach enables propellers from one vehicle to repair another, and allows operators to maintain inventories of interchangeable parts without requiring specialized knowledge of proprietary systems.

Inventive Principle:

Principle #6Universality (Multi-functionality)

4Manufacturing precision

If factory sealed designs are used, then manufacturing precision is improved, but ease of repair in field deteriorates

Engineering Contradiction:

Improveseal integrityVSAvoidfield serviceability

Core Design Contradiction:

Manufacturing precisionVSEase of repair

Solution Approach 1:

The sealed vehicle hull is segmented with standardized access points and modular attachments. This allows the maintain sealed integrity for manufacturing precision while enabling field replacement of modules through the segmented interfaces, combining the benefits of sealing with field serviceability.

Inventive Principle:

Principle #1Segmentation

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

Enables cost-effective, adaptable, and flexible UUVs that can be reconfigured for various missions, reducing production costs and operator expenses, and minimizing mission disruptions from component failures.

Implementation Method 1

using magnets and ball bearings to minimize hull penetrations

Methodology Applied

Scientific EffectMagnetic attraction: Magnetism

Implementation Method 2

using magnets and ball bearings to minimize hull penetrations

Methodology Applied

Scientific EffectFriction reduction: Ball Bearing

Data Source

PatentUS12522330B2Systems and methods for the modular attachment of additively manufactured components on vehicles

Publication Date: 2026.01.13 THE UNITED STATES OF AMERICA AS REPRESENTED BY THE SECRETARY OF THE NAVY

AI summary

Systems and methods are provided for using an additively manufactured vehicle, such as an UUV, with additively manufactured modules. The vehicle may be configurable such that additively manufactured modules or components may be detachably connected to the vehicle by hand, without the use of tools. Such modules may include connectors adapted to securely attach additional modules that may be detached by hand, without the use of tools. The additively manufactured modules may include ball bearings for rotating modules such as propellers and thrusters, and clips or tabs for detachable connection. The modules may include optical components for communications between a swarm of unmanned vehicles. Such optical modules for underwater vehicles may utilize nephelometry and/or turbidimetry to improve communications parameters based on scattered light measurements.