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NASA NTRS1987

Structural Assembly Demonstration Experiment (SADE)

The purpose of the Structural Assembly Demonstration Experiment (SADE) was to create a near-term Shuttle flight experiment focusing on the deployment and erection of structural truss elements. The activities of the MIT Space Systems Laboratory consist of three major areas: preparing and conducting neutral buoyancy simulation test series; producing a formal SADE Experiment plan; and studying the structural dynamics issues of the truss structure. Each of these areas is summarized.

Akin, David L.↗

NASA NTRS2002

Ultralightweight Space Deployable Primary Reflector Demonstrator

A concept has been developed and analyzed and several generational prototypes built for a gossamer-class deployable truss for a mirror or reflector with many smaller precisely-figured solid elements attached will, for at least the next several decades, minimize the mass of a large primary mirror assembly while still providing the high image quality essential for planet-finding and cosmological astronomical missions. Primary mirror segments are mounted in turn on ultralightweight thermally-formed plastic panels that hold clusters of mirror segments in rigid arrays whose tip/tilt and piston would be corrected over the scale of the plastic panels by the control segments. Prototype panels developed under this program are 45 cm wide and fabricated from commercially available Kaplan sheets. A three-strut octahedral tensegrity is the basis for the overall support structure. Each fundamental is composed of two such octahedrons, rotated oppositely about a common triangular face. Adjacent modules are joined at the nodes of the upper and lower triangles to form a deployable structure that could be made arbitrarily large. A seven-module dowel-and-wire prototype has been constructed. Deployment techniques based on the use of collapsing toggled struts with diagonal tensional elements allows an assembly of tensegrities to be fully collapsed and redeployed. The prototype designs will be described and results of a test program for measuring strength and deformation will be presented.

Montgomery, Edward E., IV↗

NASA NTRS2001

DTFM Modeling and Analysis Method for Gossamer Structures

Gossamer systems are mostly composed of support structures formed by highly flexible, long tubular elements and pre-tensioned thin-film membranes. These systems offer order-of-magnitude reductions in mass and launch volume and will revolutionize the architecture and design of space flight systems that require large in-orbit configurations and apertures. A great interest has been generated in recent years to fly gossamer systems on near-term and future space missions. Modeling and analysis requirements for gossamer structures are unique. Simulation of in-space performance issues of gossamer structures, such as inflation deployment of flexible booms, formation and effects of wrinkle in tensioned membranes, synthesis of tubular and membrane elements into a complete structural system, usually cannot be accomplished by using the general-purpose finite-element structural analysis codes. This has led to the need of structural modeling and analysis capabilities specifically suitable for gossamer structures. The Distributed Transfer Function Method (DTFM) can potentially meet this urgent need. Additional information is contained in the original extended abstract.

Fang, Hou-Fei↗

NASA NTRS1996

Torsional Buckling Tests of a Simulated Solar Array

Spacecraft solar arrays are typically large structures supported by long, thin deployable booms. As such, they may be particularly susceptible to abnormal structural behavior induced by mechanical and thermal loading. One example is the Hubble Space Telescope solar arrays which consist of two split tubes fit one inside the other called BiSTEMs. The original solar arrays on the Hubble Space Telescope were found to be severely twisted following deployment and later telemetry data showed the arrays were vibrating during daylight to night and night to daylight transition. The solar array twist however can force the BiSTEM booms to change in cross-section and cause tile solar arrays to react unpredictably to future loading. The solar arrays were redesigned to correct for tile vibration, however, upon redeployment they again twisted. To assess the influence of boom cross-sectional configuration, experiments were conducted on two types of booms, (1)booms with closed cross-sections, and (2) booms with open cross-sections. Both models were subjected to compressive loading and imposed tip deflections. An existing analytical model by Chung and Thornton was used to define the individual load ranges for each model solar array configuration. The load range for the model solar array using closed cross-section booms was 0-120 Newtons and 0-160 Newtons for the model solar array using open cross-section booms. The results indicate the model solar array with closed cross-section booms buckled only in flexure. However, the results of the experiment with open cross-section booms indicate the model solar array buckled only in torsion and with imposed tip deflections the cross section can degrade by rotation of the inner relative to the outer STEM. For tile Hubble Space Telescope solar arrays the results of these experiments indicate the twisting resulted from the initial mechanical loading of the open cross-section booms.

Thornton, E. A.↗

NASA NTRS2003

Thin Film Technology Development for the Powersphere

The Aerospace Corporation, NASA Glenn Research Center, Lockheed-Martin, and ILC Dover over the past two years have been engaged in developing a Multifunctional Inflatable Structure for the Powersphere Concept under contract with NASA (NAS3-01115). The Powersphere concept consists of a relatively large spherical solar array, which would be deployed from a microsatellite. The Powersphere structure and the deployment method was patented by the Aerospace Corporation (U.S. Patent Numbers 6,284,966 B 1 and 6,3 18,675). The work on this project has resulted in a number of technological innovations in the state of the art for integrating flexible thin-film solar cells with flex circuit harness technology and inflatable ultraviolet-light-rigidizable structures. The specific power, specific volume, for the Powersphere are presented in Figures 1 and 2 as a function of solar cell technology and efficiency. The Powersphere will enable microsatellite missions across NASA enterprises and DoD missions by providing ample electric power at an affordable cost. The Powersphere design provides attitude-independent electric power and thermal control for an enclosed microsatellite payload. The design is scalable, robust in high radiation environments and provides sufficient electric power to allow the use of electric propulsion. Electric propulsion enables precise positioning of microsatellites which is required for inspectors that would be deployed to inspect the International Space Station, Space Shuttle or large unmanned spacecraft. The Powersphere allows for efficient launch packaging versus deployed volume as shown in Figure 3.

Simburger, Edward J.↗

NASA NTRS1987

Experimental characterization of deployable trusses and joints

The structural dynamic properties of trusses are strongly affected by the characteristics of joints connecting the individual beam elements. Joints are particularly significant in that they are often the source of nonlinearities and energy dissipation. While the joints themselves may be physically simple, direct measurement is often necessary to obtain a mathematical description suitable for inclusion in a system model. Force state mapping is a flexible, practical test method for obtaining such a description, particularly when significant nonlinear effects are present. It involves measurement of the relationship, nonlinear or linear, between force transmitted through a joint and the relative displacement and velocity across it. An apparatus and procedure for force state mapping are described. Results are presented from tests of joints used in a lightweight, composite, deployable truss built by the Boeing Aerospace Company. The results from the joint tests are used to develop a model of a full 4-bay truss segment. The truss segment was statically and dynamically tested. The results of the truss tests are presented and compared with the analytical predictions from the model.

Ikegami, R.↗

NASA NTRS1981

The 15th Aerospace Mechanisms Symposium

The purpose of the symposium was to provide a forum for the interchange of information among those active in the field of mechanism technology. To that end, 27 papers were presented on aeronautics and space flight, with special emphasis on actuators and aerospace applications for pointing systems, latches, connectors, and other mechanisms for large space structures. The papers were authored by engineers from a broad aerospace spectrum including the U. S. aerospace industry, NASA, and several European participants. Technological areas covered include: aerospace propulsion; aerodynamic devices; crew safety; space vehicle control; spacecraft deployment, positioning, and pointing; deployable antennas/reflectors; and large space structures. Devices for payload deployment, payload retention, and crew extravehicular activities on the space shuttle orbiter are also described.

Actuators↗

NASA NTRS2005

Evaluation of Microbolometer-Based Thermography for Gossamer Space Structures

In August 2003, NASA's In-Space Propulsion Program contracted with our team to develop a prototype on-board Optical Diagnostics System (ODS) for solar sail flight tests. The ODS is intended to monitor sail deployment as well as structural and thermal behavior, and to validate computational models for use in designing future solar sail missions. This paper focuses on the thermography aspects of the ODS. A thermal model was developed to predict local sail temperature variations as a function of sail tilt to the sun, billow depth, and spectral optical properties of front and back sail surfaces. Temperature variations as small as 0.5 C can induce significant thermal strains that compare in magnitude to mechanical strains. These thermally induced strains may result in changes in shape and dynamics. The model also gave insight into the range and sensitivity required for in-flight thermal measurements and supported the development of an ABAQUS-coupled thermo-structural model. The paper also discusses three kinds of tests conducted to 1) determine the optical properties of candidate materials; 2) evaluate uncooled microbolometer-type infrared imagers; and 3) operate a prototype imager with the ODS baseline configuration. (Uncooled bolometers are less sensitive than cooled ones, but may be necessary because of restrictive ODS mass and power limits.) The team measured the spectral properties of several coated polymer samples at various angles of incidence. Two commercially available uncooled microbolometer imagers were compared, and it was found that reliable temperature measurements are feasible for both coated and uncoated sides of typical sail membrane materials.

Miles, Jonathan J.↗

NASA NTRS1986

Latch for Telescoping Structures

Latch for three-member telescoping column developed for deployment of antenna 122 meters in diameter. Deployable column along axis of antenna open lattice structure with three longerons as principal loadbearing members. Column divided into telescoping sections that deploy, one section at time. Latch automatically locks sections into position during deployment and unlocks them when antenna restowed. Latch is four-bar linkage using over-center principle for locking, with Belleville spring washers to absorb deflections.

Ahl, Elvin L., Jr.↗

NASA NTRS2010

Full-Scale Crash Test of a MD-500 Helicopter with Deployable Energy Absorbers

A new externally deployable energy absorbing system was demonstrated during a full-scale crash test of an MD-500 helicopter. The deployable system is a honeycomb structure and utilizes composite materials in its construction. A set of two Deployable Energy Absorbers (DEAs) were fitted on the MD-500 helicopter for the full-scale crash demonstration. Four anthropomorphic dummy occupants were also used to assess human survivability. A demonstration test was performed at NASA Langley's Landing and Impact Research Facility (LandIR). The test involved impacting the helicopter on a concrete surface with combined forward and vertical velocity components of 40-ft/s and 26-ft/s, respectively. The objectives of the test were to evaluate the performance of the DEA concept under realistic crash conditions and to generate test data for validation of dynamic finite element simulations. Descriptions of this test as well as other component and full-scale tests leading to the helicopter test are discussed. Acceleration data from the anthropomorphic dummies showed that dynamic loads were successfully attenuated to within non-injurious levels. Moreover, the airframe itself survived the relatively severe impact and was retested to provide baseline data for comparison for cases with and without DEAs.

Kellas, Sotiris↗

NASA NTRS2001

Modeling and Analysis of Structural Dynamics for a One-Tenth Scale Model NGST Sunshield

New modeling and analysis techniques have been developed for predicting the dynamic behavior of the Next Generation Space Telescope (NGST) sunshield. The sunshield consists of multiple layers of pretensioned, thin-film membranes supported by deployable booms. Modeling the structural dynamic behavior of the sunshield is a challenging aspect of the problem due to the effects of membrane wrinkling. A finite element model of the sunshield was developed using an approximate engineering approach, the cable network method, to account for membrane wrinkling effects. Ground testing of a one-tenth scale model of the NGST sunshield were carried out to provide data for validating the analytical model. A series of analyses were performed to predict the behavior of the sunshield under the ground test conditions. Modal analyses were performed to predict the frequencies and mode shapes of the test article and transient response analyses were completed to simulate impulse excitation tests. Comparison was made between analytical predictions and test measurements for the dynamic behavior of the sunshield. In general, the results show good agreement with the analytical model correctly predicting the approximate frequency and mode shapes for the significant structural modes.

Johnston, John↗

NASA NTRS2011

Umbilical Deployment Device

The landing scheme for NASA's next-generation Mars rover will encompass a novel landing technique (see figure). The rover will be lowered from a rocket-powered descent stage and then placed onto the surface while hanging from three bridles. Communication between the rover and descent stage will be maintained through an electrical umbilical cable, which will be deployed in parallel with structural bridles. The -inch (13-mm) umbilical cable contains a Kevlar rope core, around which wires are wrapped to create a cable. This cable is helically coiled between two concentric truncated cones. It is deployed by pulling one end of the cable from the cone. A retractable mechanism maintains tension on the cable after deployment. A break-tie tethers the umbilical end attached to the rover even after the cable is cut after touchdown. This break-tie allows the descent stage to develop some velocity away from the rover prior to the cable releasing from the rover deck, then breaks away once the cable is fully extended. The descent stage pulls the cable up so that recontact is not made. The packaging and deployment technique can store a long length of cable in a relatively small volume while maintaining compliance with the minimum bend radius requirement for the cable being deployed. While the packaging technique could be implemented without the use of break-ties, they were needed in this design due to the vibratory environment and the retraction required by the cable. The break-ties used created a series of load-spikes in the deployment signature. The load spikes during the deployment of the initial three coils of umbilical showed no increase between the different temperature trials. The cold deployment did show an increased load requirement for cable extraction in the region where no break-ties were used. This increase in cable drag was superimposed on the loads required to rupture the last set of break-ties, and as such, these loads saw significant increase when compared to their ambient counterparts. While the loads showed spikes of high magnitude, they were of short duration. Because of this, neither the deployment of the rover, nor the motion of the descent stage, would be adversely affected. In addition, the umbilical was found to have a maximum of 1.2 percent chance for recontact with the ultra-high frequency antenna due to the large margin of safety built in.

Shafer, Michael W.↗

NASA NTRS2007

Development of a Deployable Nonmetallic Boom for Reconfigurable Systems of Small Modular Spacecraft

Launch vehicle payload capacity and the launch environment represent two of the most operationally limiting constraints on space system mass, volume, and configuration. Large-scale space science and power platforms as well as transit vehicles have been proposed that greatly exceed single-launch capabilities. Reconfigurable systems launched as multiple small modular spacecraft with the ability to rendezvous, approach, mate, and conduct coordinated operations have the potential to make these designs feasible. A key characteristic of these proposed systems is their ability to assemble into desired geometric (spatial) configurations. While flexible and sparse formations may be realized by groups of spacecraft flying in close proximity, flyers physically connected by active structural elements could continuously exchange power, fluids, and heat (via fluids). Configurations of small modular spacecraft temporarily linked together could be sustained as long as needed with minimal propellant use and reconfigured as often as needed over extended missions with changing requirements. For example, these vehicles could operate in extremely compact configurations during boost phases of a mission and then redeploy to generate power or communicate while coasting and upon reaching orbit. In 2005, NASA funded Phase 1 of a program called Modular Reconfigurable High-Energy Technology Demonstrator Assembly Testbed (MRHE) to investigate reconfigurable systems of small spacecraft. The MRHE team was led by NASA's Marshall Space Flight Center and included Lockheed Martin's Advanced Technology Center (ATC) in Palo Alto and its subcontractor, ATK. One of the goals of Phase 1 was to develop an MRHE concept demonstration in a relevant 1-g environment to highlight a number of requisite technologies. In Phase 1 of the MRHE program, Lockheed Martin devised and conducted an automated space system assembly demonstration featuring multipurpose free-floating robots representing Spacecraft in the newly built Controls and Automation Laboratory (CAL) at the ATC. The CAL lab features a 12' x 24' granite air-bearing table and an overhead simulated starfield. Among the technologies needed for the concept demo were mating interfaces allowing the spacecraft to dock and deployable structures allowing for adjustable separation between spacecraft after a rigid connection had been established. The decision to use a nonmetallic deployable boom for this purpose was driven by the MRHE concept demo requirements reproduced in Table 1.

Rehnmark, Fredrik↗

NASA NTRS1980

Deployable and erectable concepts for large spacecraft

Computerized structural sizing techniques were used to determine structural proportions of minimum mass tetrahedral truss platforms designed for low Earth and geosynchronous orbit. Optimum (minimum mass) deployable and erectable, hexagonal shaped spacecraft are sized to satisfy multiple design requirements and constraints. Strut dimensions characterizing minimum mass designs are found to be significantly more slender than those conventionally used for structural applications. Comparison studies show that mass characteristics of deployable and erectable platforms are approximately equal and that the shuttle flights required by deployable trusses become excessive above certain critical stiffness values. Recent investigations of eractable strut assembly are reviewed. Initial erectable structure assembly experiments show that a pair of astronauts can achieve EVA assembly times of 2-5 min/strut and studies indicate that an automated assembler can achieve times of less than 1 min/strut for around the clock operation.

Bush, H. G.↗

NASA NTRS1979

An 11-meter deployable truss for the SEASAT radar antenna

A folding three dimensional truss and tripod assembly which deploys the SEASAT Synthetic Aperture Radar Antenna is described. The folding structure with the antenna panels and rf components stows in an 8.5-inch-thick package. Upon deployment, the structure produced is a flat and rigid support for the antenna.

Campbell, B. E.↗

NASA NTRS1990

Adaptive structures - Test hardware and experimental results

The facilities and procedures used at JPL to test adaptive structures such as the large deployable reflector (LDR) are described and preliminary results are reported. The applications of adaptive structures in future NASA missions are outlined, and the techniques which are employed to modify damping, stiffness, and isolation characteristics, as well as geometric changes, are listed. The development of adaptive structures is shown to be effective as a result of new actuators and sensors, and examples are listed for categories such as fiber optics, shape-memory materials, piezoelectrics, and electrorheological fluids. Some ground test results are described for laboratory truss structures and truss test beds, which are shown to be efficient and easy to assemble in space. Adaptive structures are shown to be important for precision space structures such as the LDR, and can alleviate ground test requirements.

Wada, Ben K.↗

NASA NTRS1983

Large space structures raise testing challenges

The testing approaches and techniques necessary for combined ground and space verification for large space structures (LSS) to be deployed and assembled in space are explored. The size of LSS precludes full ground tests, thereby requiring assemblies, components, and their interactions to be examined on orbit. Ground tests involving drop tests and zero-g aircraft flights can be performed with scale models, but need computational compensation to eliminate gravitational and torque effects that do not occur in space. Structural rigidity also varies from ground to space, and can partly be accounted for in ground tests by using cable supports, although numerical modelling must remove the effects of the cables' presence. Long-term funding is recommended for on-orbit tests of components in order to build a data base for later testing and actual construction of LSS.

Hanks, B. R.↗

NASA NTRSDate not supplied

Commissioning the James Webb Space Telescope Optical Telescope Element

The James Webb Space Telescope (JWST) launched on December 25th, 2021. The observatory was deployed and commissioned during its first six months. The Optical Telescope Element includes both large deployments of the Deployable Tower Assembly, Secondary Mirror Support Structure and the Primary Mirror Wings and it includes the deployment and alignment of the 18 primary mirror segments and the secondary mirror. The initial phase included cooldown and ice mitigation efforts followed by telescope deployments, mirror deployment and wavefront sensing and control. This paper will discuss the entire OTE commissioning from deployment through alignment including a discussion of results and lessons learned.

Lee D Feinberg↗