Interface Design for On-Orbit Assembly of Space Telescopes

Abstract

Traditional spacecraft design has reached the limits of size and volume that current launchers allow. This is especially true for space telescopes (James Webb), where size is directly correlated with performance. A solution to this is on-orbit assembly, however some enabling technologies are insufficiently developed. One of the most important factors is the design of standardized interfaces for modular designs (only three existing designs). This thesis proposes a mechanical interface design - including data and electrical transfer - meant to allow the assembly of a modular platform (including all spacecraft subsystems except the mirror segments) upon which a support layer and a mirror layer can be built/assembled. The design presents a unique mechanism allowing for assembly outside of the platform plane direction, thus allowing disassembly of a minimal amount of modules in the event of servicing. Three different iterations of the design were considered, and simulations for both the assembly and assembled state have been performed in ANSYS. To compare performance with existing interfaces, a scaled down model was simulated. The results of the preliminary simulations show a performance increase of at least 200% for each load case. A physical prototype was manufactured and tested, however destructive testing was not performed.