Rapid assembly of spacecraft structures for responsive space

The ORS office has been chartered with developing the architecture that will allow a customized satellite to be designed, produced, deployed, and operational within a matter of days [1]. Every aspect of the spacecraft development process needs to be reassessed in order to achieve this ambitious responsive spacecraft architecture. Assembly, integration & testing could be drastically reduced by stocking component-ready modular panels for assembly., However, the assembly of the structure itself needs to be change from the current process of securing panels with dozens of mixed-size fasteners and the associated verification, tooling, and documentation. Additionally, the new process must take into consideration the need to pass electrical and thermal connections throughout the satellite bus in a time-effective manner. A method for rapidly providing a stiff mechanical attachment across panels of a spacecraft bus while simultaneously providing electrical and thermal continuity would help to realize the goals of ORS. In collaboration with the Air Force Research Laboratory/Space Vehicles Directorate, Honeybee Robotics Spacecraft Mechanisms Corporation has developed a fastening strategy for enabling rapid assembly of a spacecraft bus structure using our patented Quick Insertion Nut (QIN) technology. □□ With this approach, a standard bolt can be rapidly inserted into the QIN and then about one turn is required to preload the connection, without significant support equipment or operator skill. These QINs are embedded in manifolds (the manifold includes panel-to-panel electrical interconnects) that together comprise a skeleton/frame for the spacecraft panels. When the panels are assembled to the manifolds, a robust structural, electrical and thermal connection for the bus is achieved. With this method, it is possible to also quickly disassemble bus panels to swap out faulty components, accommodate upgrades, or support last-minute component changes to satisfy changing mission needs. While the concept is simple, when extrapolated across the multiple fasteners in a typical spacecraft bus (the time for threading of each bolt alone is eight to ten times faster), this results in a revolutionary decrease in the amount of time required for spacecraft assembly. With adequate margin and analysis, it may be possible that time-consuming dedicated system-level analysis and tests could also be eliminated from the AI&T process. View the video of our feasibility demonstration using a subscale prototype at: http://www.honeybeerobotics.com/168/Assembly4.mov - a representative “corner” of three satellite panels assembled using the QIN fasteners, manifold and electrical connection.