Unit design and splicing scheme for a modular assembled mesh antenna

Abstract

In-orbit assembly technology is a promising direction for large space structures, which combines numbers of small identical or similar units into one large assembly. This paper proposes a modular assembled mesh antenna constituted by several hexagonal platform units. The principle and configuration of using approximate hexagonal platform units to constitute a spherical truss is first investigated. Then, considering the units’ non-interference, assembly sequence and interchangeability, detailed unit mechanical design with docking interface and splicing scheme is addressed. The whole mesh antenna is a pre-stressed structure caused by the inner-unit cable mesh pretension and the outer-unit assembly stress. So, considering both the surface accuracy and the low-stress assembly requirement, an optimization strategy is put forward. Low docking force and assembly stress can be achieved by optimizing the cable mesh’s pretension and the docking points’ initial position. Finally, a case study is illustrated. Compared with the form-finding method without considering assembly, the antenna unit designed using the proposed optimization strategy exhibits smaller contact forces during assembly, and smaller RMS error after assembly, which still meets the design requirement.