3.4.2.2. 4 Manufacturing Module - The manufacturing module processes flat stock into basic structural element tri-beams. Figure 3.4-8 shows the application of these modules for manufacture of beams using aluminum. The basic operations for aluminum beam manufacture include roll forming the flat strip stock into the required longeron and intercostal elements of the beam. Feed and cropping mechanisms ensure proper member lengths. Spot welding is used to join longerons and intercostals. Harvesting arms and associated mechanisms are used to assemble the end fittings. Beam manufacture using graphite/epoxy could utilize rolled strips of partially cured composite materials. A series of hot and cold rollers would be used to finalize the setting process. Bonding devices are used to join elements. A preliminary operations analysis of the manufacturing steps indicates that beams can roughly be manufactured at the rate of 420 Ib/hr. The weight estimate shown in Fig. 3.4-8 uses the RAM free flying payload module for the basic spacecraft and a 100% wrap around factor to account for manufacturing equipments. Significantly more study is required to define the module concept for a more realistic estimate. 3.4. 2. 2.5 Space Station - Figure 3.4-22 is a schematic of a basic six-man Space Station needed to support assembly operations at a 7000 n mi altitude site. Information presented in Ref 25 was used to establish weight and cost estimates. To achieve consistency of data, the $/lb non-recurring and recurring cost estimates for the Space Station established in Ref 25 has been applied to the cost of all support equipment (RMM, RAM, Support Modules, etc.). Figure 3.4-23 is the weight and cost estimates for a 12-man support Space Station, and has been used to establish the weight and cost trends as a function of number of crew members. 3.4.2.2. 6 Crew Transport Module - Reference 27 was used to establish a strawman for the crew transport module, Fig. 3.4-24. The conceptual design of this module can be used to transport crews between the Shuttle and the support Space Station at 7000 n mi using the Space Tug as a propulsion stage. It also has the operational capability for servicing the manufacturing modules and remote manipulator modules.
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