An Overview of the NASA Advanced Composite Solar Sail (ACS3) Technology Demonstration Project
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solar sails↗
Engineering topics
Marco Straubel
Publications and source records attributed to Marco Straubel.
Full Scale Flat Floor Testing of a 500-M2-Class Solar Sail Deployer
Solar sailing missions rely on deployable systemsfor large area to mass ratios once in space, whilestill being small enough for launcher envelopes inthe stowed configuration. Many of thesedeployable systems feature booms that areflattened and subsequently coiled onto aspool/hub. As part of a collaborative deployablespace structures research effort of NASA and DLR,a boom deployment mechanism for a future 500 m²solar sail has been developed since 2017. To achieve the respective solar sail size goal, 16.5m long booms produced by NASA were integratedinto a DLR-designed deployer mechanism. Thisconsiderable size, as well as the lightweightconstruction of the booms and respectivedeployable systems makes ground testing asignificant challenge. Some systems for gravitycompensation and boom alignment will bepresented in the paper. However, the main focus isthe functional flat floor testing of the integratedboom-deployment mechanism system, as well asits challenges. The testing performed includes full deployment aswell as stowage of the booms. Both have beenperformed multiple times. The latter is one of thekey parameters determining packaging efficiency,which in turn confirms design assumptions. Duringsystem development, small scale tests and modelshave been used in preparation of flat floor testingof the 33 m span cross of the full-scale booms anddeployment mechanism. Hence a small chapter isalso devoted to analysing the differences inbehaviour between small- and full-scaledeployment systems. More parameters that are vital to design decisionshave been determined this way, such as drivingbelt force or hub brake torque. This paper alsofocuses on development goals and needs forfuture steps to achieve higher levels of technologyreadiness, such as the balancing of driving motorforce, synchronisation of its transmission and thecountering hub brake torque
Deployment mechanism↗
Experimental Methods Using Force Application of A Single Boom for A 500-M²-Class Solar Sail
Solar sailing missions rely on deployable systems for large area-to-mass ratios once in space, while still being small enough for launcher envelopes in the stowed configuration. Many of these deployable systems feature booms that are flattened and subsequently coiled onto a spool / hub. As part of a collaborative deployable space structures research effort between the National Aeronautics and Space Administration (NASA) and German Aerospace Center (DLR), a boom deployment system for a future 500 m² solar sail has been developed. To achieve the respective solar sail size goal, 16.5-m-long booms produced by NASA were integrated into a DLR-designed deployer mechanism. This considerable size, as well as the lightweight construction of the booms and respective deployable systems makes testing on the ground a significant challenge. Some systems for gravity compensation as well as vertical testing to minimize the influence of gravity have been used in the past. However, an uncertainty factor remains towards the behaviour in the space environment. The focus of this paper is the load application testing of the integrated boom-deployment mechanism system under microgravity condition, as well as a comparison to vertical testing under gravity. Testing in microgravity was performed during a parabolic flight test inside an aircraft and it included stowage and full deployment of a single boom along the longitudinal axis of the aircraft. The load application was split into two categories: static testing, which induced a linear force ramp to the static boom for either compression or compression-bending; and dynamic testing, which applied a constant force to a boom during extension provided by the deployer mechanism. Both types of tests were performed multiple times at two distinct lengths of the boom, fully deployed (12.76 m) and ~28.6 % deployed (3.65 m). More parameters that are vital to the test philosophy are the angles of attack in the force application and the highest force applied. The data acquisition used for the applied load and deflection measurements of the boom is also presented.
Martin Richter↗
Design and Testing of the BionicWingSat in a Zero-g Flight Campaign - A 2U-CubeSat with Deployable, Biologically-Inspired Wings
In this paper, recent developments in the design, manufacturing, and testing of a novel deployable structure with several potential applications in space will be described. Through a cooperative effort of the German Aerospace Center (DLR) and the National Aeronautics and Space Administration (NASA), a biologically inspired structurally integrated membrane featuring distributed functional elements has been developed and tested in a 2U CubeSat called BionicWingSat. Such a membrane structure could be useful for several applications in which a relatively flat area is desirable such as solar sails, drag sails, or solar shades. For SmallSats and CubeSats, the design proposed also has the desirable property of being self-deploying without the need for powered deployment mechanisms. Building on previous work inspired by the wings of earwigs, the research presented in this paper includes structural design of self-deploying hinges, a survey of various advanced additive layer manufacturing (ALM) methods for making hinges, mechanical characterization of the hinges, and finite element analysis (FEA) of the hinges. In this work, the conflicting goals of maximizing deployed structural stiffness, maximizing deployed area, maximizing stowed packaging efficiency, and maximizing resistance to creep when stowed must be considered. The resulting design concept is a gossamer structure that cannot support its own weight in gravity. For this reason, a focus in this paper is on a parabolic flight test campaign in which 24 fully integrated wings on two BionicWingSats were tested in a microgravity environment. From this test campaign, several lessons were learned regarding the wing design and procedures for carrying out microgravity tests of this manner.
CubeSat↗
Design and Testing of the BionicWingSat in a Zero-g Flight Campaign - A 2U-CubeSat with Deployable, Biologically-Inspired Wings
In this paper, recent developments in the design, manufacturing, and testing of a novel deployable structure with several potential applications in space will be described. Through a cooperative effort of the German Aerospace Center (DLR) and the National Aeronautics and Space Administration (NASA), a biologically inspired structurally integrated membrane featuring distributed functional elements has been developed and tested in a 2U CubeSat called BionicWingSat. Such a membrane structure could be useful for several applications in which a relatively flat area is desirable such as solar sails, drag sails, or solar shades. For SmallSats and CubeSats, the design proposed also has the desirable property of being self-deploying without the need for powered deployment mechanisms. Building on previous work inspired by the wings of earwigs, the research presented in this paper includes structural design of self-deploying hinges, a survey of various advanced additive layer manufacturing (ALM) methods for making hinges, mechanical characterization of the hinges, and finite element analysis (FEA) of the hinges. In this work, the conflicting goals of maximizing deployed structural stiffness, maximizing deployed area, maximizing stowed packaging efficiency, and maximizing resistance to creep when stowed must be considered. The resulting design concept is a gossamer structure that cannot support its own weight in gravity. For this reason, a focus in this paper is on a parabolic flight test campaign in which 24 fully integrated wings on two BionicWingSats were tested in a microgravity environment. From this test campaign, several lessons were learned regarding the wing design and procedures for carrying out microgravity tests of this manner.
CubeSat↗
Experimental Methods Using Force Application of A Single Boom for A 500-M²-Class Solar Sail
Solar sailing missions rely on deployable systems for large area-to-mass ratios once in space, while still being small enough for launcher envelopes in the stowed configuration. Many of these deployable systems feature booms that are flattened and subsequently coiled onto a spool / hub. As part of a collaborative deployable space structures research effort between the National Aeronautics and Space Administration (NASA) and German Aerospace Center (DLR), a boom deployment system for a future 500 m² solar sail has been developed. To achieve the respective solar sail size goal, 16.5-m-long booms produced by NASA were integrated into a DLR-designed deployer mechanism. This considerable size, as well as the lightweight construction of the booms and respective deployable systems makes testing on the ground a significant challenge. Some systems for gravity compensation as well as vertical testing to minimize the influence of gravity have been used in the past. However, an uncertainty factor remains towards the behaviour in the space environment. The focus of this paper is the load application testing of the integrated boom-deployment mechanism system under microgravity condition, as well as a comparison to vertical testing under gravity. Testing in microgravity was performed during a parabolic flight test inside an aircraft and it included stowage and full deployment of a single boom along the longitudinal axis of the aircraft. The load application was split into two categories: static testing, which induced a linear force ramp to the static boom for either compression or compression-bending; and dynamic testing, which applied a constant force to a boom during extension provided by the deployer mechanism. Both types of tests were performed multiple times at two distinct lengths of the boom, fully deployed (12.76 m) and ~28.6 % deployed (3.65 m). More parameters that are vital to the test philosophy are the angles of attack in the force application and the highest force applied. The data acquisition used for the applied load and deflection measurements of the boom is also presented.
Martin Richter↗
Zero-G Experiments of the BionicWingsat - A 2U-Cubesat with Deployable, Biologically-Inspired Wings
In this paper, recent testing of a novel deployable structure with several potential applications in space will be described, with the focus on performed deployment experiments in a DLR Zero-g flight campaign and in ground tests. Through a cooperative effort of the German Aerospace Center (DLR) and the National Aeronautics and Space Administration (NASA), a biologically-inspired structurally-integrated membrane featuring distributed functional elements has been developed and integrated into the 2U CubeSat called BionicWingSat. Such a membrane structure could be useful for all sorts of applications in which a relatively flat area is desirable such as solar sails, drag sails, or solar shades. For SmallSats and CubeSats, the design proposed also has the desirable property of being self-deploying without the need for powered deployment mechanisms. Building on previous work inspired by the wings of earwigs, the research presented in this paper focuses on testing of developed design concepts for such structural systems. To do so 24 fully integrated wings on two BionicWingSats in 2U Cubesat format were experimentally deployed in a microgravity environment during a dedicated DLR Zero-g flight campaign in 2021. The results of these experiments, the built hardware and test articles, the test arrangement, as well as a comparison to ground tests are discussed in this paper.
Spacecraft structures↗