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Experimental Setup for Mechanically Testing Subscale Triangular, Rollable, and Collapsible Deployable Composite Booms

High-strain composite deployable space structures are used for space infrastructure and science applications such as solar array supports, antennae, camera masts, and lightweight structures supporting solar sailing propulsion ele-ments. Triangular, Rollable, and Collapsible (TRAC) deployable composite booms are one example of a high-strain composite deployable structure and were studied using novel experimental test and characterization methods developed under the Gravity Offloading and Analysis of Long Imperfection-sensitive Ele-ments (GOALIE) project. In the present work, a subscale 7-m-long TRAC boom was suspended vertically to orient gravity along the length of the boom. By ori-enting vertically, highly nonlinear and unstable behavior often encountered dur-ing horizontally oriented gravity offload testing of similar structures was reduced. Pretest analytical predictions of TRAC booms indicated three unique failure modes, loads, and locations for three unique loading cases of in-plane bending, out-of-plane bending, and axial compression. To investigate the predicted behav-ior, an experimental test was set up to impart mechanical loads to a subscale TRAC boom. The experimental setup, loading cases, and instrumentation used to characterize the mechanical response of a subscale TRAC boom are described in this paper.

High-strain composites

Bistable Deployable Composite Booms With Parabolic Cross-Sections

This paper investigates how stable equilibrium states in the extended and coiled configurations can be predicted in thin-shelled composite booms with parabolic cross-sections. These conic shapes potentially offer greater stiffness properties when compared to circular cross-sections, which is critical for improving the load bearing performance of deployed booms. Inducing bistability through the choice of composite shell layups in parabolic booms would allow for controllable self-deployment due to a less energetic coiled state when compared to monostable booms. An inextensional analytical model is used to predict the stable coiled diameters of tape spring and Collapsible Tubular Mast (CTM) booms with parabolic cross-sections. The parabolic section is discretized into circular segments using biarc spline interpolation, which allows them to be integrated into the strain energy minimization procedure used to obtain the equilibrium states. When the parabolic booms are parametrically compared against circular booms with identical layups, flattened height, and mass, the former are found to generally have better stiffness performance while being less efficient in stowed volume as evidenced by larger coiled diameters. Analytical coiled diameters and their strain energy are verified with finite element simulations for optimal parabolic tape spring and CTM booms.

Andrew J. Lee

Nutation Damper System

The Nutation Damper System is a three function mechanism designed for the Galileo Spacecraft, a spin stabilized deep-space probe to Jupiter. By damping the movement of a large deployable science boom acting as an outboard pendulum, the nutation damper rapidly stabilizes the spacecraft from dynamic irregularities. The system includes the boom deployment device and the ultra-low friction boom hinge. This paper describes the mechanism, the degree to which friction, stiction and lost motion have been eliminated, and the unique test methods that allow its performance to be measured.

Sevilla, D. R.

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

Experimental Characterization of the Dimensional Stability of Deployable Composite Booms During Stowage

Thin-ply carbon fiber reinforced polymer materials offer the opportunity to create long thin-shell booms with high strength to weight ratios. These booms can be rolled up and stowed in small volumes to be later deployed. These features make them ideal for use in gossamer solar sails as well as other deployable space structures. It has been observed that stowing the booms in rolled-up configurations can cause time-dependent deformations. A comprehensive understanding of the detrimental effects of stowing the coiled booms is necessary to implement these structures in spaceflight missions. During stowage inside the spacecraft, the boom is subjected to a constant deformation/strain that causes it to relax over time, measurable by a decrease in stress. Using large deformation bending tests, the complete fold-stow-unfold-recover cycle of thin-laminate candidates for the rollable booms is characterized. Further bending and stowage testing is done at the boom level. The results from this test campaign will be used to evaluate the dimensional stability of deployable booms made from thin-ply composites that exhibit visco-elasto-plastic behavior and calibrate and validate numerical finite element models that include visco-elasto-plastic material models.

Experimental Characterization

Analysis of the Lenticular Jointed MARSIS Antenna Deployment

This paper summarizes important milestones in a yearlong comprehensive effort which culminated in successful deployments of the MARSIS antenna booms in May and June of 2005. Experimentally measured straight section and hinge properties are incorporated into specialized modeling techniques that are used to simulate the boom lenticular joints. System level models are exercised to understand the boom deployment dynamics and spacecraft level implications. Discussion includes a comparison of ADAMS simulation results to measured flight data taken during the three boom deployments. Important parameters that govern lenticular joint behavior are outlined and a short summary of lessons learned and recommendations is included to better understand future applications of this technology.

Dynamic

Feasibility study of a 110 watt per kilogram lightweight solar array system

The feasibility of a 10,000 watt solar array panel which has a minimum power-to-mass ratio of 110 watt/kg is discussed. The application of this ultralightweight solar array to three possible missions was investigated. With the interplanetary mission as a baseline, the constraining requirements for a geosynchronous mission and for a manned space station mission are presented. A review of existing lightweight solar array system concepts revealed that changes in the system approach are necessary to achieve the specified 110 watt/kg goal. A comprehensive review of existing component technology is presented in the areas of thin solar cells, solar cell covers, welded interconnectors, substrates and deployable booms. Advances in the state-of-the-art of solar cell and deployable boom technology were investigated. System level trade studies required to select the optimum boom bending stiffness, system aspect ratio, bus voltage level, and solar cell circuit arrangement are reported. Design analysis tasks included the thermal analysis of the solar cell blanket, thermal stress analysis of the solar cell interconnectors/substrate, and the thermostructural loading of the deployed boom.

Shepard, N. F.

Re-Flight of the Deployable Retrievable Booms

The Tethered Satellite System (TSS), a scientific payload which was flown on STS-46 and again on STS-75, included two satellite-mounted Deployable Retrievable Booms (DRB's). The system was launched aboard the Space Shuttle Atlantis in July 1992. However, because of the problems which occurred at the original attempted deployment of the Tethered Satellite, the DRBs were never operated on-orbit during the STS-46 mission. In postflight functional tests, both DRB's failed to relatch properly. This paper discusses the troubleshooting of the anomalies, design changes, and DRB operational constraints incorporated for the STS-75 mission

Foster, C. L.

Study of a 30-M Boom For Solar Sail-Craft: Model Extendibility and Control Strategy

Space travel propelled by solar sails is motivated by the fact that the momentum exchange that occurs when photons are reflected and/or absorbed by a large solar sail generates a small but constant acceleration. This acceleration can induce a constant thrust in very large sails that is sufficient to maintain a polar observing satellite in a constant position relative to the Sun or Earth. For long distance propulsion, square sails (with side length greater than 150 meters) can reach Jupiter in two years and Pluto in less than ten years. Converting such design concepts to real-world systems will require accurate analytical models and model parameters. This requires extensive structural dynamics tests. However, the low mass and high flexibility of large and light weight structures such as solar sails makes them unsuitable for ground testing. As a result, validating analytical models is an extremely difficult problem. On the other hand, a fundamental question can be asked. That is whether an analytical model that represents a small-scale version of a solar-sail boom can be extended to much larger versions of the same boom. To answer this question, we considered a long deployable boom that will be used to support the solar sails of the sail-craft. The length of fully deployed booms of the actual solar sail-craft will exceed 100 meters. However, the test-bed we used in our study is a 30 meter retractable boom at MSFC. We first develop analytical models based on Lagrange s equations and the standard Euler-Bernoulli beam. Then the response of the models will be compared with test data of the 30 meter boom at various deployed lengths. For this stage of study, our analysis was limited to experimental data obtained at 12ft and 18ft deployment lengths. The comparison results are positive but speculative. To observe properly validate the analytic model, experiments at longer deployment lengths, up to the full 30 meter, have been requested. We expect the study to answer the extendibility question of the analytical models. In operation, rapid temperature changes can be induced in solar sails as they transition from day to night and vice versa. This generates time dependent thermally induced forces, which may in turn create oscillation in structural members such as booms. Such oscillations have an adverse effect on system operations, precise pointing of instruments and antennas and can lead to self excited vibrations of increasing amplitude. The latter phenomenon is known as thermal flutter and can lead to the catastrophic failure of structural systems. To remedy this problem, an active vibration suppression system has been developed. It was shown that piezoelectric actuators used in conjunction with a Proportional Feedback Control (PFC) law (or Velocity Feedback Control (VFC) law) can induce moments that can suppress structural vibrations and prevent flutter instability in spacecraft booms. In this study, we will investigate control strategies using piezoelectric transducers in active, passive, and/or hybrid control configurations. Advantages and disadvantages of each configuration will be studied and experiments to determine their capabilities and limitations will be planned. In particular, special attention will be given to the hybrid control, also known as energy recycling, configuration due to its unique characteristics.

Keel, Leehyun

Vibration Control of Deployable Astromast Boom: Preliminary Experiments

This paper deals with the dynamic characterization of a flexible aerospace solar boom. The modeling issues and sine dwell vibration testing to determine natural frequencies and mode shapes of a continuous-longer on deployable ASTROMAST lattice boom are discussed. The details of the proof-of-concept piezoelectric active vibration experiments on a simple cantilever beam to control its vibrations are presented. The control parameters like voltage to the controller crystal and its location are investigated, to determine the effectiveness of control element to suppress selected resonant vibrations of the test specimen. Details of this experiment and plans for its future adaptation to the prototype structure are also discussed.

Swaminadham, M.

Tethered satellite control mechanism

The tethered satellite control mechanisms consist of four major subsystems. The reel drive mechanism stores the tether. It is motor driven and includes a level wind to uniformly feed the tether to the reel. The lower boom mechanism serves two primary functions: (1) it measures tether length and velocity as the tether runs through the mechanism, and (2) it reads the tether tension at the reel. It also provides change the direction for the tether from the reel to the upper boom mechanism. The deployment boom positions the upper boom mechanism with satellite out of the cargo bay. The deployment function places the 500-kg satellite 20 m away from the Space Shuttle (producing a small natural gravity gradient force), impacts an initial velocity to the satellite for deployment, and allows for satellite docking at a safe distance from the body of the Space Shuttle. The upper boom mechanism (UBM) services three functions: (1) it provides tether control to the satellite as the satellite swings in and out of plane; (2) it reads tether tension in the low range during the early deployment and final retrieval parts of the mission; and (3) it produces additional tether tension at the reel when tether tension to the satellite is in the low range.

Kyrias, G. M.

Folding, articulated, square truss

A larger, stronger deployable boom was developed to handle the requirements of larger, heavier payloads in space. The main components of the boom and its deployer are described and their functions explained. Desirable features of the boom are identified and physical properties are reported.

Warden, Robert M.

Cable-catenary large antenna concept

Deployable to very large diameters (over 1000 ft), while still remaining compatible with a complete satellite system launch by STS, the cable-catenary antenna comprises: 8 radial deployable boom masts; a deployable hub and feed support center mast; balanced front and back, radial and circumferential catenary cabling for highly accurate (mm) surface control; no interfering cabling in the antenna field; and an RF reflecting mesh supported on the front catenaries. Illustrations show the antenna-satellite system deployed and stowed configurations; the antenna deployment sequence; the design analysis logic; the sizing analysis output, and typical parametric design data.

Akle, W.

Boom Retraction Mechanism as Part of Sample Acquisition System from Remote and Hazardous Extra-Terrestrial Sites

This paper discusses the development of a mechanism as part of a comet sampling system. The mechanism, known by the acronym BRAD for Boom Retraction and Deployment, is part of a mission proposal to return a comet regolith sample to earth. The mission proposal; CORSAIR for Comet Rendezvous, Sample Acquisition, Investigation, and Return, was coordinated by Johns Hopkins Applied Physics Lab in Laurel, MD as a response to the NASA 2017 New Frontiers AO or Announcement of Opportunity. BRAD functions as a means to tend and control a deployable boom that connects a sample projectile to the spacecraft.

Comet Sample Acquisition Mechanism

Analysis of Meteorological Satellite location and data collection system concepts

A satellite system that employs a spaceborne RF interferometer to determine the location and velocity of data collection platforms attached to meteorological balloons is proposed. This meteorological advanced location and data collection system (MALDCS) is intended to fly aboard a low polar orbiting satellite. The flight instrument configuration includes antennas supported on long deployable booms. The platform location and velocity estimation errors introduced by the dynamic and thermal behavior of the antenna booms and the effects of the presence of the booms on the performance of the spacecraft's attitude control system, and the control system design considerations critical to stable operations are examined. The physical parameters of the Astromast type of deployable boom were used in the dynamic and thermal boom analysis, and the TIROS N system was assumed for the attitude control analysis. Velocity estimation error versus boom length was determined. There was an optimum, minimum error, antenna separation distance. A description of the proposed MALDCS system and a discussion of ambiguity resolution are included.

Wallace, R. G.

Stiffening of deployable space booms: Automated Protein Crystal Growth Facility

Part of the curriculum for the seniors at Vanderbilt University in the Mechanical Engineering Program is to take a design class. The purpose of the class is to expose the students to the open ended problems which working engineers are involved with every day. In the past, the students have been asked to work in a variety of projects developed by the professor. This year Vanderbilt was admitted into the Advanced Design Program (ADP) sponsored by the Universities Space Research Association (USRA) and the National Aeronautics and Space Association (NASA). The grant sponsored undergraduate design and research into new and innovative areas in which NASA is involved. The grant sponsors the Teaching Assistant as well as provides monies for travel and other expenses. The design and research of the seniors of the 1992-1993 school year in association with NASA and USRA is documented.

Cruse, Thomas