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The term adaptive structures refers to a structural control approach in which sensors, actuators, electronics, materials, structures, structural concepts, and system-performance-validation strategies are integrated to achieve specific objectives.
High and low intensity dynamic environments experienced by a spacecraft during launch and on-orbit operations, respectively, induce structural loads and motions, which are difficult to reliably predict. Structural dynamics in low- and mid-frequency bands are sensitive to component interface uncertainty and non-linearity as evidenced in laboratory testing and flight operations. Analytical tools for prediction of linear system response are not necessarily adequate for reliable prediction of mid-frequency band dynamics and analysis of measured laboratory and flight data. A new MATLAB toolbox, designed to address the key challenges of mid-frequency band dynamics, is introduced in this paper. Finite-element models of major subassemblies are defined following rational frequency-wavelength guidelines. For computational efficiency, these subassemblies are described as linear, component mode models. The complete structural system model is composed of component mode subassemblies and linear or non-linear joint descriptions. Computation and display of structural dynamic responses are accomplished employing well-established, stable numerical methods, modern signal processing procedures and descriptive graphical tools. Parametric sensitivity and Monte-Carlo based system identification tools are used to reconcile models with experimental data and investigate the effects of uncertainties. Models and dynamic responses are exported for employment in applications, such as detailed structural integrity and mechanical-optical-control performance analyses.
This paper presents a mass-based trade study for large-scale deployable triangular trusses, where the longerons can be monocoque tubes, isogrid tubes, or coilable longeron trusses. Such structures are typically used to support heavy reflectors, solar panels, or other instruments, and are subject to thermal gradients that can vary a great deal based on orbital altitude, location in orbit, and self-shadowing. While multi layer insulation (MLI) blankets are commonly used to minimize the magnitude of these thermal disturbances, they subject the truss to a nonstructural mass penalty. This paper investigates the impact of these add-on thermal protection layers on selecting the lightest precision structure for a given loading scenario.
We describe a robotic platform for traversing and manipulating a modular 3D lattice structure. The robot is designed to operate within a specifically structured environment, which enables low numbers of degrees of freedom (DOF) compared to robots performing comparable tasks in an unstructured environment. This allows for simple controls, as well as low mass and cost. This approach, designing the robot relative to the local environment in which it operates, results in a type of robot we call a "relative robot." We describe a bipedal robot that can locomote across a periodic lattice structure, as well as being able to handle, manipulate, and transport building block parts that compose the lattice structure. Based on a general inchworm design, the robot has added functionality for traveling over and operating on a host structure.
We describe analytical methods for the design of the discrete elements of ultralight lattice structures. This modular, building block strategy allows for relatively simple element manufacturing, as well as relatively simple robotic assembly of low mass density structures on orbit, with potential for disassembly and reassembly into highly varying and large structures. This method also results in a structure that is easily navigable by relatively small mobile robots. The geometry of the cell can allow for high packing efficiency to minimize wasted payload volume while maximizing structural performance and constructability. We describe the effect of geometry choices on the final system mechanical properties, manufacturability of the components, and automated robotic constructability of a final system. Geometry choices considered include building block complexity, symmetry of the unit cell, and effects of vertex, edge, and face connectivity of the unit cell. Mechanical properties considered include strength scaling, modulus scaling, and structural performance of the joint, including proof load, shear load, mass, and loading area; as well as validation and verification opportunities. Manufacturability metrics include cost and time, manufacturing method (COTS versus custom), and tolerances required. Automated constructability metrics include local effects of loads imparted to the structure by the robot and assembly complexity, encompassing the ability of the robot to clamp and number of placement motions needed for assembly.
We describe analytical methods for the design of the discrete elements of ultralight lattice structures. This modular, building block strategy allows for relatively simple element manufacturing, as well as relatively simple robotic assembly of low mass density structures on orbit, with potential for disassembly and reassembly into highly varying and large structures. This method also results in a structure that is easily navigable by relatively small mobile robots. The geometry of the cell can allow for high packing efficiency to minimize wasted payload volume while maximizing structural performance and constructability. We describe the effect of geometry choices on the final system mechanical properties and automated robotic constructability of a final system. Geometric properties considered include number of attachments per voxel, number of attachments per coefficient of volume, and effects of vertex, edge, and face connectivity of the unit cell. Mechanical properties considered include strength scaling, modulus scaling, and packing efficiency of the lattice. Automated constructibility metrics include volume allowance for an end-effector, strut clearance angle for an end-effector, and packing efficiency. These metrics were applied to six lattice unit cell geometries: cube, cuboctahedron, octahedron, octet, rhombic dodecahedron, and truncated octahedron. A case study is presented to determine the most suitable lattice system for a specific set of strength and modulus scaling requirements while optimizing for ease of robotic assembly.
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The DOE Lab Director's Conference identified the need for the DOE National Laboratories to actively and aggressively pursue ways to apply DOE technology to problems of national need. Space structures are key elements of DOD and NASA space systems and a space technology area in which DOE can have a significant impact. LASC is a joint agency space technology experiment (DOD Phillips, NASA Marshall, and DOE Sandia). The topics are presented in viewgraph form and include the following: phase 4 investigator testbed; control of large flexible structures in orbit; INFLEX; Controls, Astrophysics; and structures experiments in space; SARSAT; and LASC mission objectives.
The development of deployable and fabricated composite trusses for large space structures by NASA and private industry is reviewed. Composite materials technology is discussed with a view toward fabrication processes and the characteristics of finished truss beams. Advances in roll-forming open section caps from graphite-composite strip material and new ultrasonic welding techniques are outlined. Vacuum- and gravity-effect test results show that the ultrasonic welding of graphite-thermoplastic materials in space is feasible. The structural characteristics of a prototype truss segment are presented. A new deployable graphite-composite truss with high packaging density for broad application to large space platforms is described.
Deployment is a candidate mode for construction of structural space systems components. By its very nature, deployment is a dynamic event, often involving large angle unfolding of flexible beam members. Validation of proposed designs and conceptual deployment mechanisms is enhanced through analysis. Analysis may be used to determine member loads thus helping to establish deployment rates and deployment control requirements for a given concept. Futhermore, member flexibility, joint free-play, manufacturing tolerances, and imperfections can affect the reliability of deployment. Analyses which include these effects can aid in reducing risks associated with a particular concept. Ground tests which can play a similar role to that of analyses are difficult and expensive to perform. Suspension systems just for vibration ground tests of large space structures in a 1 g environment present many challenges. Suspension of a structure which spatially expands is even more challenging. Analysis validation through experimental confirmation on relatively small simple models would permit analytical extrapolation to larger more complex space structures.
The development of a geodetic beam and beam builder for on orbit construction of large truss type space structures is discussed. The geodetic beam is a lightweight, open lattice structure composed of an equilateral gridwork of crisscrossing rods. The beam provides a high degree of stiffness and minimizes structural distortion, due to temperature gradients, through the incorporation of a new graphite and glass reinforced thermoplastic composite material with a low coefficient of thermal expansion. A low power consuming, high production rate, beam builder automatically fabricates the geodetic beams in space using rods preprocessed on Earth. Three areas of the development are focused upon; (1) geodetic beam designs for local attachment of equipment or beam to beam joining in a parallel or crossing configurations, (2) evaluation of long life pultruded rods capable of service temperatures higher than possible with the HMS/P1700 rod material, and (3) evalaution of high temperature joint encapsulant materials.