Research on Lean and Accurate Method for High Throughput Satellite Payload Modules' Assembly Process

High throughput satellites use payload technologies such as multi-point beamforming and frequency multiplexing, and the number and mass of individual payloads, as well as the number of payload channels, are much higher than traditional communication satellites. Higher requirements have been put forward for the quality and speed of the final assembly process of the payload module. On the basis of analysis of the characteristics and assembly difficulties of high-throughput satellite payload modules, this paper systematically proposes a complete set of digital assembly methods. This paper puts forward innovative assembly methods, such as establish routing design method and assembly method for large scale waveguide, and improving inspection methods. This set of final assembly methods has improved the overall assembly efficiency by over 50% in the actual practice of the Chinasat-26 satellite's payload module, which has been accurately achieved in only once. The final assembly results of the payload module of Chinasat-26 satellite fully demonstrate that this process method is a guideline with strong operability, with good applicability in the design and implementation of complex spacecraft such as high-throughput satellites.