Abstract: A method of accurately applying maskant to a workpiece using one or more scanned laser beams and a maskant delivery device. The method includes the interaction of the laser beams with the maskant material while the material is in transit to, and after it has reached the surface of, the workpiece. Other features of the method include: laser roughening of application surfaces and laser melting of maskant to enhance adhesion of the maskant, laser measurement of maskant edges and correction of detected edge errors, and suppression of maskant ignition by forced ventilation and inert gas environments.

Abstract: An electrochemical machining process for the production of integrally stiffened shell and plate structures. The process applies to such structures as isogrid, waffle, ring stiffened and stringer stiffened structures. In these structures, secondary rib stiffening patterns are generated and shaped by inducing protrustions at selectively positioned electrolyte feeder orifices in electrode tools. Fillets and blending radii between ribs and skins as well as the thickness and width variations of the skins and ribs are controlled to enhance structural performance through electrode tool shaping, and control of electrolyte flow, applied voltage, electrolyte pressure, and electrode oscillation.

Abstract: An improved parts orbiter for use in a chem-milling vat. The orbiter has a major frame assembly that is self standing which is lowered into the chem-milling vat. A minor frame assembly is positioned within the major frame assembly and it is pivotally mounted thereto about a horizontal axis. A first motor is connected to a drive sprocket gear, a chain, and a driven sprocket gear for rotating the minor frame assembly about the horizontal axis. A planetary gear is mounted on a shaft extending upwardly from the bottom cross member of the minor frame assembly. Its teeth are in meshing engagement with a sun gear that is mounted on a shaft whose one end passes through one of the horizontal side members of the minor frame assembly and has its end also passing through one of the upright side members of the major frame assembly. A second drive motor is connected through a drive sprocket gear, a chain, and a driven gear which itself is also mounted on the same shaft that the sun gear is mounted on.

Abstract: Disclosed is an expandable panel and truss structure capable of being stowed in a storage container (canister) for transportation into space and deployed to form structures such as antennas, solar panels or similar space or terrestial structures. The antenna formed comprises the panels stored as hinged pairs (sets) folded in accordian-like fashion together with the expandable trusses and other devices necessary for antenna space operation, such as attitude control and antenna feed. The panel sets are deployed from the canister to form a toroidal ring, circular in cross-section when deployed, for supporting the antenna lens and to form a feed support boom utilizing the canister as part of the antenna structure. The canister is connected to the ring and support boom in the deployed state by the expandable trusses. A fully automatic system is included for deploying the antenna and for holding the antenna structure in its deployed state.

Abstract: An automated assembly, maintenance, and repair system for the construction of a large space structure. The space structure comprises a plurality of trusses and truss junctions that in turn are made up of a plurality of individual struts and nodes. The truss assemblies are progressively built by an assembler trolley as the trolley crawls along the constructed truss. The trolley comprises a forward crawler and a rear crawler joined by an articulated coupler. The crawlers are carried along the structure by belt transports incorporating grippers that engage the truss structure at the nodes. Manipulator arms for strut and node assembly are located on the forward crawler, and the majority of control, power, and communication systems are located in the rear crawler. Cargo canisters filled with component parts for constructing the space structure are carried by the forward crawler. The space structure configuration is determined by the arrangement of the individual struts and nodes during the assembly process.

Abstract: An automated assembly, maintenance, and repair system for the construction of a large space structure. The space structure comprises a plurality of trusses and truss junctions that in turn are made up of a plurality of individual struts and nodes. The truss assemblies are progressively built by an assembler trolley as the trolley crawls along the constructed truss. The trolley comprises a forward crawler and a rear crawler joined by an articulated coupler. The crawlers are carried along the structure by belt transports incorporating grippers that engage the truss structure at the nodes. Manipulator arms for strut and node assembly are located on the forward crawler, and the majority of control, power, and communication systems are located in the rear crawler. Cargo canisters filled with component parts for constructing the space structure are carried by the forward crawler. The space structure configuration is determined by the arrangement of the individual struts and nodes during the assembly process.

Abstract: An automated assembly, maintenance, and repair system for the construction of a large space structure. The space structure comprises a plurality of trusses and truss junctions that in turn are made up of a plurality of individual struts and nodes. The truss assemblies are progressively built by an assembler trolley as the trolley crawls along the constructed truss. The trolley comprises a forward crawler and a rear crawler joined by an articulated coupler. The crawlers are carried along the structure by belt transports incorporating grippers that engage the truss structure at the nodes. Manipulator arms for strut and node assembly are located on the forward crawler, and the majority of control, power, and communication systems are located in the rear crawler. Cargo canisters filled with component parts for constructing the space structure are carried by the forward crawler. The space structure configuration is determined by the arrangement of the individual struts and nodes during the assembly process.

Abstract: An automated assembly, maintenance, and repair system for the construction of a large space structure. The space structure comprises a plurality of trusses and truss junctions that in turn are made up of a plurality of individual struts and nodes. The truss assemblies are progressively built by an assembler trolley as the trolley crawls along the constructed truss. The trolley comprises a forward crawler and a rear crawler joined by an articulated coupler. The crawlers are carried along the structure by belt transports incorporating grippers that engage the truss structure at the nodes. Manipulator arms for strut and node assembly are located on the forward crawler, and the majority of control, power, and communication systems are located in the rear crawler. Cargo canisters filled with component parts for constructing the space structure are carried by the forward crawler. The space structure configuration is determined by the arrangement of the individual struts and nodes during the assembly process.

Abstract: An automated assembly, maintenance, and repair system for the construction of a large space structure. The space structure comprises a plurality of trusses and truss junctions that in turn are made up of a plurality of individual struts and nodes. The truss assemblies are progressively built by an assembler trolley as the trolley crawls along the constructed truss. The trolley comprises a forward crawler and a rear crawler joined by an articulated coupler. The crawlers are carried along the structure by belt transports incorporating grippers that engage the truss structure at the nodes. Manipulator arms for strut and node assembly are located on the forward crawler, and the majority of control, power, and communication systems are located in the rear crawler. Cargo canisters filled with component parts for constructing the space structure are carried by the forward crawler. The space structure configuration is determined by the arrangement of the individual struts and nodes during the assembly process.

Abstract: A mechanism for deploying and retracting an isogrid structure particularly suited for use in supporting low weight reflective or absorbtive surfaces, characterized by a plurality of hinged isogrid panels stowed in an accordion folded stack arranged for automatic deployment into a long continuous strip or array. Two deployment arms in contact with the stack of panels are rotated to a position perpendicular to the stack, carrying with them a perforated deployment tape that is attached to the first panel. The tape is engaged to sprocket drives which draw the first panel from the stack. Thereafter, the panels are extended by the powered sprockets which engage perforations in the panel edges. A shutter sequentially releases pairs of panels during deployment. For retraction, the sprockets drive the panels back toward the stack where a creaser arm hinges pairs of panels which are thereafter folded into a stack by means of the shutter capturing and stowing each folded pair of panels.

Abstract: A mechanism for deploying and retracting an isogrid structure particularly suited for use in supporting low weight reflective or absorbtive surfaces, characterized by a plurality of hinged isogrid panels stowed in an accordian folded stack arranged for deployment into a long continuous strip or array. Two deployment frames in contact with the stack of panels are rotated to a position perpendicular to the stack. Attached at the outermost ends of each panel hinge are panel rollers. In the accordian folded position, these rollers are alternately located near the top and bottom of the folded stack. The deployment frames each contain an arced raceway for engagement of the upper panel rollers and a straight raceway for engagement of the lower rollers. An upper roller travels down the arced raceway thereby progressively unfolding a pair of hinged panels until they are flat and lie in the deployment plane where they are subsequently extended into the deployed position.

Abstract: A gun mount is constructed of a plurality of alternately curved and flat isogrid plates arranged, annularly about and extending upward from a generally circular base, the plates being secured together to define a generally U-shaped shell-like structure having a pair of spaced apart upwardly extending trunnion support members, the grid structure of the flat plates consisting of an uniform unflanged isogrid structure which terminates at a pocketed transition section on three sides and a stiffened edge along the top, and the grid structure of the curved sections consisting of radial grid members which are intersected by curved diagonal grid members describing exponential spirals.

Abstract: A mechanism for deploying and retracting an isogrid structure particularly suited for use in supporting low weight reflective or absorbtive surfaces, characterized by a plurality of hinged isogrid panels stowed in an accordian folded stack arranged for automatic deployment into a long continuous strip or array. Two deployment arms in contact with the stack of panels are rotated to a position perpendicular to the stack, carrying with them the first panels. Thereafter the panels are extended by powered sprockets which engage the panel edges. A shutter bar sequentially releases pairs of panels during deployment. For retraction, the sprockets drive the panels back toward the stack where a creaser bar hinges pairs of panels which are thereafter folded into a stack by means of the shutter bar capturing and stowing each folded pair of panels.

Abstract: An isogrid structure having inset strips of composite materials at the top and bottom of the grid webs. A preferably flanged isogrid basically consists of I-beam members arranged in an integral repeating pattern of substantially equilateral triangles. One flange may be integral with a skin sheet covering the structure. At least some of these flanges are provided with grooves running parallel to the beam webs, filled with advanced composite materials comprising high-strength fibers in a supporting matrix. Preferably, the fibers run parallel to the beam webs. Preferred arrangements of the fibers are described.

Abstract: A high strength frusto-conical or conical structure utilizing an integral flanged reinforcing grid is disclosed. The structure comprises a skin plate having a generally conical shape, with a plurality of upstanding integral ribs. At least some of the ribs are configured in evenly spaced right and left spirals. Other ribs may extend along conic generatrix intersecting the spiral ribs at points where right and left spiral ribs intersect. Each rib includes a narrow flange at the inner edge, lying substantially parallel to the skin.