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Shape Memory Composite Hybrid Hinge

There are two conventional types of hinges for in-space deployment applications. The first type is mechanically deploying hinges. A typical mechanically deploying hinge is usually composed of several tens of components. It is complicated, heavy, and bulky. More components imply higher deployment failure probability. Due to the existence of relatively moving components among a mechanically deploying hinge, it unavoidably has microdynamic problems. The second type of conventional hinge relies on strain energy for deployment. A tape-spring hinge is a typical strain energy hinge. A fundamental problem of a strain energy hinge is that its deployment dynamic is uncontrollable. Usually, its deployment is associated with a large impact, which is unacceptable for many space applications. Some damping technologies have been experimented with to reduce the impact, but they increased the risks of an unsuccessful deployment. Coalescing strain energy components with shape memory composite (SMC) components to form a hybrid hinge is the solution. SMCs are well suited for deployable structures. A SMC is created from a high-performance fiber and a shape memory polymer resin. When the resin is heated to above its glass transition temperature, the composite becomes flexible and can be folded or packed. Once cooled to below the glass transition temperature, the composite remains in the packed state. When the structure is ready to be deployed, the SMC component is reheated to above the glass transition temperature, and it returns to its as-fabricated shape. A hybrid hinge is composed of two strain energy flanges (also called tape-springs) and one SMC tube. Two folding lines are placed on the SMC tube to avoid excessive strain on the SMC during folding. Two adapters are used to connect the hybrid hinge to its adjacent structural components. While the SMC tube is heated to above its glass transition temperature, a hybrid hinge can be folded and stays at folded status after the temperature is reduced to below its glass transition temperature. After the deployable structure is launched in space, the SMC tube is reheated and the hinge is unfolded to deploy the structure. Based on test results, the hybrid hinge can achieve higher than 99.999% shape recovery. The hybrid hinge inherits all of the good characteristics of a tape-spring hinge such as simplicity, light weight, high deployment reliability, and high deployment precision. Conversely, it eliminates the deployment impact that has significantly limited the applications of a tape-spring hinge. The deployment dynamics of a hybrid hinge are in a slow and controllable fashion. The SMC tube of a hybrid hinge is a multifunctional component. It serves as a deployment mechanism during the deployment process, and also serves as a structural component after the hinge is fully deployed, which makes a hybrid hinge much stronger and stiffer than a tape-spring hinge. Unlike a mechanically deploying hinge that uses relatively moving components, a hybrid hinge depends on material deformation for its packing and deployment. It naturally eliminates the microdynamic phenomenon.

Fang, Houfei↗

Got Mercury?

Many of the operational and payload lighting units used in various spacecraft contain elemental mercury. If these devices were damaged on-orbit, elemental mercury could be released into the cabin. Although there are plans to replace operational units with alternate light sources, such as LEDs, that do not contain mercury, mercury-containing lamps efficiently produce high quality illumination and may never be completely replaced on orbit. Therefore, exposure to elemental mercury during spaceflight will remain possible and represents a toxicological hazard. Elemental mercury is a liquid metal that vaporizes slowly at room temperature. However, it may be completely vaporized at the elevated operating temperatures of lamps. Although liquid mercury is not readily absorbed through the skin or digestive tract, mercury vapors are efficiently absorbed through the respiratory tract. Therefore, the amount of mercury in the vapor form must be estimated. For mercury releases from lamps that are not being operated, we utilized a study conducted by the New Jersey Department of Environmental Quality to calculate the amount of mercury vapor expected to form over a 2-week period. For longer missions and for mercury releases occurring when lamps are operating, we conservatively assumed complete volatilization of the available mercury. Because current spacecraft environmental control systems are unable to remove mercury vapors, both short-term and long-term exposures to mercury vapors are possible. Acute exposure to high concentrations of mercury vapors can cause irritation of the respiratory tract and behavioral symptoms, such as irritability and hyperactivity. Chronic exposure can result in damage to the nervous system (tremors, memory loss, insomnia, etc.) and kidneys (proteinurea). Therefore, the JSC Toxicology Group recommends that stringent safety controls and verifications (vibrational testing, etc.) be applied to any hardware that contains elemental mercury that could yield airborne mercury vapor concentrations greater than 0.1 mg/cu m in the total spacecraft atmosphere for exposures lasting 30 days or less or 0.01 mg/cu m mercury vapor for exposures lasting more than 30 days. We also encourage the use of alternative devices that do not contain mercury.

Meyers, Valerie E.↗

An Overview of Wind-Driven Rovers for Planetary Exploration

The use of in-situ propulsion is considered enabling technology for long duration planetary surface missions. Most studies have focused on stored energy from chemicals extracted from the soil or the use of soil chemicals to produce photovoltaic arrays. An older form of in-situ propulsion is the use of wind power. Recent studies have shown potential for wind driven craft for exploration of Mars, Titan and Venus. The power of the wind, used for centuries to power wind mills and sailing ships, is now being applied to modern land craft. Efforts are now underway to use the wind to push exploration vehicles on other planets and moons in extended survey missions. Tumbleweed rovers are emerging as a new type of wind-driven science platform concept. Recent investigations by the National Aeronautics and Space Administration (NASA) and Jet Propulsion Laboratory (JPL) indicate that these light-weight, mostly spherical or quasi-spherical devices have potential for long distance surface exploration missions. As a power boat has unique capabilities, but relies on stored energy (fuel) to move the vessel, the Tumbleweed, like the sailing ships of the early explorers on earth, uses an unlimited resource the wind to move around the surface of Mars. This has the potential to reduce the major mass drivers of robotic rovers as well as the power generation and storage systems. Jacques Blamont of JPL and the University of Paris conceived the first documented Mars wind-blown ball in 1977, shortly after the Viking landers discovered that Mars has a thin CO2 atmosphere with relatively strong winds. In 1995, Jack Jones, et al, of JPL conceived of a large wind-blown inflated ball for Mars that could also be driven and steered by means of a motorized mass hanging beneath the rolling axis of the ball. A team at NASA Langley Research Center started a biomimetic Tumbleweed design study in 1998. Wind tunnel and CFD analysis were applied to a variety of concepts to optimize the aerodynamic characteristics of the Tumbleweed Rovers. Bare structures, structures carrying sails and a tumbleweed plant (of the Salsola genus) were tested in Langley's wind tunnels. Thomas Estier of the Swiss Federal Institute of Technology developed a memory metal collapsible structure, the Windball. Numerous other researchers have also suggested spherical rovers.

Hajos, Gregory A.↗

Optimization of Car Body under Constraints of Noise, Vibration, and Harshness (NVH), and Crash

To be competitive on the today's market, cars have to be as light as possible while meeting the Noise, Vibration, and Harshness (NVH) requirements and conforming to Government-man dated crash survival regulations. The latter are difficult to meet because they involve very compute-intensive, nonlinear analysis, e.g., the code RADIOSS capable of simulation of the dynamics, and the geometrical and material nonlinearities of a thin-walled car structure in crash, would require over 12 days of elapsed time for a single design of a 390K elastic degrees of freedom model, if executed on a single processor of the state-of-the-art SGI Origin2000 computer. Of course, in optimization that crash analysis would have to be invoked many times. Needless to say, that has rendered such optimization intractable until now. The car finite element model is shown. The advent of computers that comprise large numbers of concurrently operating processors has created a new environment wherein the above optimization, and other engineering problems heretofore regarded as intractable may be solved. The procedure, shown, is a piecewise approximation based method and involves using a sensitivity based Taylor series approximation model for NVH and a polynomial response surface model for Crash. In that method the NVH constraints are evaluated using a finite element code (MSC/NASTRAN) that yields the constraint values and their derivatives with respect to design variables. The crash constraints are evaluated using the explicit code RADIOSS on the Origin 2000 operating on 256 processors simultaneously to generate data for a polynomial response surface in the design variable domain. The NVH constraints and their derivatives combined with the response surface for the crash constraints form an approximation to the system analysis (surrogate analysis) that enables a cycle of multidisciplinary optimization within move limits. In the inner loop, the NVH sensitivities are recomputed to update the NVH approximation model while keeping the Crash response surface constant. In every outer loop, the Crash response surface approximation is updated, including a gradual increase in the order of the response surface and the response surface extension in the direction of the search. In this optimization task, the NVH discipline has 30 design variables while the crash discipline has 20 design variables. A subset of these design variables (10) are common to both the NVH and crash disciplines. In order to construct a linear response surface for the Crash discipline constraints, a minimum of 21 design points would have to be analyzed using the RADIOSS code. On a single processor in Origin 2000 that amount of computing would require over 9 months! In this work, these runs were carried out concurrently on the Origin 2000 using multiple processors, ranging from 8 to 16, for each crash (RADIOSS) analysis. Another figure shows the wall time required for a single RADIOSS analysis using varying number of processors, as well as provides a comparison of 2 different common data placement procedures within the allotted memories for each analysis. The initial design is an infeasible design with NVH discipline Static Torsion constraint violations of over 10%. The final optimized design is a feasible design with a weight reduction of 15 kg compared to the initial design. This work demonstrates how advanced methodology for optimization combined with the technology of concurrent processing enables applications that until now were out of reach because of very long time-to-solution.

Kodiyalam, Srinivas↗