Optimization of Space Station components using design code CometBoards Original Research Article

Weight minimization is an important requirement in the design of components of the Space Station, since it can directly save launch cost, reduce the number of space shuttle missions, and facilitate on orbit assembly and fabrication. Preliminary optimum designs for such flight components are obtained using a design tool, termed ‘CometBoards’ and utilizing an animation feature of PATRAN software. Salient features of CometBoards include multiple non-linear programming optimizers; industrial strength analyzers; component synthesis concepts through a design variable formulation; constraint grouping scheme; and substructuring optimization technique, etc. The optimum design capability of CometBoards is illustrated using two flight components: (a) a ‘spacer structure’ of the solar power module of the Space Station, and (b) a ‘support system’ for integration in the space shuttle cargo bay. Optimum designs for both components have been obtained for multiple pseudo-static flight loads for behavior constraints confirming to specifications of the Space Station. The design optimization process generated lighter structures, with a reduction in the weights of about one third those obtained by the traditional manual design. Brief organization of CometBoards, description of the Space Station components, their design environments, behavior limitations, dynamic animation via PATRAN, along with the optimum designs are presented in this paper.