Control moment gyroscopes including rotors having radially-compliant spokes and methods for the manufacture thereof

1. A control moment gyroscope (CMG), comprising: a stator housing; an inner gimbal assembly (IGA), comprising: an IGA housing rotatably mounted to the stator housing; a CMG rotor rotatably mounted to the IGA housing, the CMG rotor comprising: a rotor shaft having a length; a rotor rim circumscribing the rotor shaft; and a plurality of radially-compliant spokes extending between the rotor shaft and the rotor rim, each radially-compliant spoke including an outer spoke end and an inner spoke end, the inner spoke end having an axial height that is closer to the length of the rotor shaft than to the axial height of the outer spoke end; wherein the plurality of radially-compliant spokes are integrally formed with the rotor shaft and the rotor rim as a single machined piece; and a spin motor coupled to the IGA housing and configured to rotate the CMG rotor about a spin axis; and a torque motor coupled to the stator housing and configured to rotate the IGA housing about a gimbal axis to generate a desired output torque during operation of the CMG.

2. A CMG according to claim 1 wherein at least a portion of each of the plurality of radially-compliant spokes is curved, as viewed along the spin axis.

3. A CMG according to claim 1 wherein each of the plurality of radially-compliant spokes comprises a tensile strain relief feature.

4. A CMG according to claim 3 wherein the tensile strain relief feature is integrally formed with the spoke body.

5. A CMG according to claim 4 wherein the tensile strain relief features comprises an undulating portion of the spoke body.

6. A CMG according to claim 4 wherein the tensile strain relief feature comprises a bifurcated portion of the spoke body, as viewed along the spin axis.

7. A CMG according to claim 4 wherein the tensile strain relief feature is defined, at least in part, by an opening formed through the rotor spoke along an axis substantially parallel to the spin axis.

8. A CMG according to claim 3 wherein each of the plurality of radially-compliant spokes further comprises:

an inner spoke end integrally joined to the rotor shaft; and

an outer spoke end integrally joined to the rotor rim, the tensile strain relief feature disposed between the inner spoke end and the outer spoke end.

9. A CMG according to claim 8 wherein the axial height of each radially-compliant spoke increases gradually when moving in a radially inward direction from the outer spoke end toward the inner spoke end.

10. A CMG according to claim 1 further comprising a supplemental rim mounted around the rotor rim.

11. A control moment gyroscope (CMG), comprising:

a stator housing;

an inner gimbal assembly (IGA), comprising:

an IGA housing rotatably mounted to the stator housing;

a CMG rotor rotatably mounted to the IGA housing, the CMG rotor comprising:

a rotor shaft;

a rotor rim disposed around the rotor shaft;

a plurality of radial spokes having spoke bodies extending between the rotor shaft and the rotor rim; and

a plurality of tensile strain relief features integrally formed with plurality of radial spokes and imparting each of the plurality of radial spokes with a predetermined radial compliancy, the plurality of tensile strain relief features comprising curved portions of the spoke bodies integrally joined to an inner circumferential surface of the rotor rim;

a spin motor coupled to the IGA housing and configured to rotate the CMG rotor about a spin axis; and

a torque motor coupled to the stator housing and configured to rotate the IGA housing about a gimbal axis perpendicular to the spin axis.

12. A CMG according to claim 11 wherein the plurality of tensile strain relief features are selected from the group consisting of undulating segments of the spoke bodies and bifurcated segments of the spoke bodies, as viewed along the spin axis.

13. A method for manufacturing a control moment gyroscope (CMG), the method comprising:

producing a monolithic CMG rotor, comprising:

a rotor shaft;

a rotor rim circumscribing the rotor shaft; and

a plurality of radially-compliant spokes extending between the rotor shaft and the rotor rim;

installing the monolithic CMG rotor within an inner gimbal assembly (IGA) including an IGA housing and a spin motor configured to rotate the monolithic CMG rotor relative to the IGA housing about a spin axis; and

mounting the IGA to a stator assembly including a stator assembly housing and a torque motor configured to selectively rotate the IGA about a gimbal axis to selectively generate a desired output torque during operation of the CMG;

wherein producing comprises:

providing a one piece rotor preform; and

cutting openings through the body of the one piece rotor preform along axes substantially parallel to the spin axis to define the plurality of radially-compliant spokes and to impart each spoke with a tensile relief feature integrally formed with the rotor shaft and with the rotor rim.

14. A method according to claim 13 wherein the step of forming comprises forming each of the plurality of radially-compliant spokes to have a curved section, as viewed along the spin axis.

15. A method according to claim 13 wherein the step of forming comprises forming each of the plurality of radially-compliant spokes to include a bifurcated section, as viewed along the spin axis.

16. A CMG according to claim 1 wherein the axial height of each inner spoke end is approximately equivalent to a radius of the CMG rotor.

17. A CMG according to claim 11 wherein the plurality of tensile strain relief features comprise S-shaped sections of the spoke bodies integrally joined to the rotor rim.

18. A CMG according to claim 11 wherein the plurality of tensile strain relief features comprise bifurcated midsections of the spoke bodies, each bifurcated midsection including bowed legs that converge while bending during rotation of the monolithic CMG rotor to allow the plurality of radially compliant spokes to lengthen.

19. A CMG according to claim 11 wherein the plurality of radial spokes each include an inner spoke end having an axial height approximately equivalent to a radius of the CMG rotor.