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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.↗

DOE OSTI2025

Wave energy in season: a comparative approach to feasibility of seasonal deployments for remote coastal communities

Remote coastal communities, which could be early adopters of wave energy projects, have concerns over costs, conflicts, and potential risks of development. Designers and developers are challenged to address these community concerns as they continue to develop wave energy technologies. One potential means of reducing costs, conflicts, and risks, especially for demonstration and pilot-scale projects, could be planning a deployment that operates for only a portion of the year—a seasonal deployment. Here, in this paper, we examine the impacts of a seasonal deployment in terms of cost, electricity production, operations and maintenance, environmental impacts, and community benefits. We take a holistic, comparative approach to feasibility that can be replicated for other comparative studies. We estimate electricity production using a point absorber WEC modeled near Sitka, AK, USA and optimized for the given sea conditions. We determine that, for remote community sized projects, seasonal deployments could result in small cost savings (less than 10 %), but larger decreases in annual energy production (around 30 % for our case study area). Seasonal deployments could be preferable in places with seasonal energy needs, if failures and device access become a major hindrance to wave energy technology development, or as a cautionary approach to introducing new technology to the oceans. We also determine that a highly seasonal wave resource is not necessarily a requirement for seasonal deployments to be considered. Seasonal deployments are an alternative to year-round deployments that can be considered in places where marine spatial conflict is a seasonal concern.

WEC optimizations↗

DOE OSTI2019

Life cycle assessment and tempo-spatial optimization of deploying dynamic wireless charging technology for electric cars

Dynamic wireless power transfer (DWPT), or dynamic wireless charging technology, enables charging-while-driving and offers opportunities for eliminating range anxiety, stimulating market penetration of electric vehicles (EVs), and enhancing the sustainability performance of electrified transportation. However, the deployment of wireless charging lanes on highways and urban road networks can be costly and resource-intensive. A life cycle assessment (LCA) is conducted here to compare the sustainability performance of DWPT applied in a network of highways and urban roads for charging electric passenger cars. The assessment compares DWPT to stationary wireless charging and to conventional plug-in charging using a case study of Washtenaw County in Michigan, USA over 20 years. The LCA is based on three key sustainability metrics: costs, greenhouse gas (GHG) emissions, and energy burdens, encompassing not only the use-phase burdens from electricity and fuel, but also the upfront deployment burdens of DWPT infrastructure. A genetic algorithm is applied to optimize the rollout of DWPT infrastructure both spatially and temporally in order to minimize life cycle costs, GHG, and energy burdens: (1) spatial optimization selects road segments to deploy DWPT considering traffic volume, speed, and pavement remaining service life (RSL); (2) temporal optimization determines in which year to deploy DWPT on a particular road segment considering EV market share growth as a function of DWPT coverage rate, future DWPT cost reduction, and charging efficiency improvement. Results indicate that optimal deployment of DWPT electrifying up to about 3% of total roadway lane-miles reduces life cycle GHG emissions and energy by up to 9.0% and 6.8%, respectively, and enables downsizing of the EV battery capacity by up to 48%, compared to the non-DWPT scenarios. Roadside solar panels and storage batteries are essential to significantly reduce life cycle energy and GHG burdens but bring additional costs. Breakeven analysis indicates a breakeven year for solar charging benefits to pay back the DWPT infrastructure burdens can be less than 20 years for GHG and energy burdens but longer than 20 years for costs. A monetization of carbon emissions of at least $250 per metric tonne of CO 2 is required to shift the optimal “pro-cost” deployment to the optimal “pro-GHG” deployment. A roadway segment with volume greater than about 26,000 vehicle counts per day, speed slower than 55 miles per hour (1 mile ≈ 1.609 km), and pavement RSL shorter than 3 years should be given a high priority for early-stage DWPT deployment.

33 ADVANCED PROPULSION SYSTEMS↗

NASA NTRS1982

Design and analysis considerations for deployment mechanisms in a space environment

On the second flight of the INTELSAT V spacecraft the time required for successful deployment of the north solar array was longer than originally predicted. The south solar array deployed as predicted. As a result of the difference in deployment times a series of experiments was conducted to locate the cause of the difference. Deployment rate sensitivity to hinge friction and temperature levels was investigated. A digital computer simulation of the deployment was created to evaluate the effects of parameter changes on deployment. Hinge design was optimized for nominal solar array deployment time for future INTELSAT V satellites. The nominal deployment times of both solar arrays on the third flight of INTELSAT V confirms the validity of the simulation and design optimization.

Vorlicek, P. L.↗

NASA NTRS1995

A simple method for verifying the deployment of the TOMS-EP solar arrays

The Total Ozone Mapping Spectrometer-Earth Probe (TOMS-EP) mission relies upon a successful deployment of the spacecraft's solar arrays. Several methods of verification are being employed to ascertain the solar array deployment status, with each requiring differing amounts of data. This paper describes a robust attitude-independent verification method that utilizes telemetry from the coarse Sun sensors (CSS's) and the three-axis magnetometers (TAM's) to determine the solar array deployment status - and it can do so with only a few, not necessarily contiguous, points of data. The method developed assumes that the solar arrays are deployed. Telemetry data from the CSS and TAM are converted to the Sun and magnetic field vectors in spacecraft body coordinates, and the angle between them is calculated. Deployment is indicated if this angle is within a certain error tolerance of the angle between the reference Sun and magnetic field vectors. Although several other methods can indicate a non-deployed state, with this method there is a 70% confidence level in confirming deployment as well as a nearly 100% certainty in confirming a non-deployed state. In addition, the spacecraft attitude (which is not known during the first orbit after launch) is not needed for this algorithm because the angle between the Sun and magnetic field vectors is independent of the spacecraft attitude. This technique can be applied to any spacecraft with a TAM and with CSS's mounted on the solar array(s).

Koppersmith, James R.↗

NASA NTRS1998

Qualification of the Tropical Rainfall Measuring Mission Solar Array Deployment System

The Tropical Rainfall Measuring Mission (TRMM) solar arrays are placed into orbital configuration by a complex deployment system. Its two wings each comprise twin seven square solar panels located by a twelve foot articulated boom. The four spring-driven hinge lines per wing are rate-limited by viscous dampers. The wings are stowed against the spacecraft kinematically, and released by five pyrotechnically-actuated mechanisms. Since deployment failure would be catastrophic, a total of 17 deployment tests were completed to qualify the system for the worst cast launch environment. This successful testing culminated in the flawless deployment of the solar arrays on orbit, 15 minutes after launch in November 1997. The custom gravity negation system used to perform deployment testing is modular to allow its setup in several locations, including the launch site in Japan. Both platform and height can be varied, to meet the requirements of the test configuration and the test facility. Its air pad floatation system meets tight packaging requirements, allowing installation while stowed against the spacecraft without breaking any flight interfaces, and avoiding interference during motion. This system was designed concurrently with the deployment system, to facilitate its installation, to aid in the integration of the flight system to the spacecraft, while demonstrating deployment capabilities. Critical parameters for successful testing were alignment of deployment axes and tables to gravity, alignment of table seams to minimize discontinuities, and minimizing pressure drops in the air supply system. Orbital performance was similar to that predicted by ground testing.

Lawrence, Jon↗

NASA NTRS2002

The Propulsive Small Expendable Deployer System (ProSEDS)

This Annual Report covers the following main topics: 1) Updated Reference Mission. The reference ProSEDS (Propulsive Small Expendable Deployer System) mission is evaluated for an updated launch date in the Summer of 2002 and for the new 80-s current operating cycle. Simulations are run for nominal solar activity condition at the time of launch and for extreme conditions of dynamic forcing. Simulations include the dynamics of the system, the electrodynamics of the bare tether, the neutral atmosphere and the thermal response of the tether. 2) Evaluation of power delivered by the tether system. The power delivered by the tethered system during the battery charging mode is computed under the assumption of minimum solar activity for the new launch date. 3) Updated Deployment Control Profiles and Simulations. A number of new deployment profiles were derived based on the latest results of the deployment ground tests. The flight profile is then derived based on the friction characteristics obtained from the deployment tests of the F-1 tether. 4) Analysis/estimation of deployment flight data. A process was developed to estimate the deployment trajectory of the endmass with respect to the Delta and the final libration amplitude from the data of the deployer turn counters. This software was tested successfully during the ProSEDS mission simulation at MSFC (Marshall Space Flight Center) EDAC (Environments Data Analysis Center).

Lorenzini, Enrico C.↗

NASA NTRS2007

Deployable System for Crash-Load Attenuation

An externally deployable honeycomb structure is investigated with respect to crash energy management for light aircraft. The new concept utilizes an expandable honeycomb-like structure to absorb impact energy by crushing. Distinguished by flexible hinges between cell wall junctions that enable effortless deployment, the new energy absorber offers most of the desirable features of an external airbag system without the limitations of poor shear stability, system complexity, and timing sensitivity. Like conventional honeycomb, once expanded, the energy absorber is transformed into a crush efficient and stable cellular structure. Other advantages, afforded by the flexible hinge feature, include a variety of deployment options such as linear, radial, and/or hybrid deployment methods. Radial deployment is utilized when omnidirectional cushioning is required. Linear deployment offers better efficiency, which is preferred when the impact orientation is known in advance. Several energy absorbers utilizing different deployment modes could also be combined to optimize overall performance and/or improve system reliability as outlined in the paper. Results from a series of component and full scale demonstration tests are presented as well as typical deployment techniques and mechanisms. LS-DYNA analytical simulations of selected tests are also presented.

Kellas, Sotiris↗

NASA NTRS2007

Deployable Landing Leg Concept for Crew Exploration Vehicle

The NASA Exploration program is investigating the merits of land landing concepts for the Crew Exploration Vehicle (CEV). Four options are under investigation: retro-rockets which fire and slow the vehicle before contact with the landing surface, deployable crushable material which deploys just before landing and crushes during land contact, airbags which deploy just before landing and deflate during land contact, and deployable legs which deploy before landing and contain material that absorbs energy during land contact. The purpose of the present work is to determine the effectiveness of the deployable leg concept. To accomplish this goal, structural models of the deployable leg concept are integrated with the Crew Model (CM) and computational simulations are performed to determine vehicle and component loadings and acceleration levels. Details of the modeling approach, deployable leg design, and resulting accelerations are provided.

Lawrence, Charles↗

NASA NTRS2004

Lightweight, Self-Deploying Foam Antenna Structures

Lightweight, deployable antennas for a variety of outer-space and terrestrial applications would be designed and fabricated according to the concept of cold hibernated elastic memory (CHEM) structures, according to a proposal. Mechanically deployable antennas now in use are heavy, complex, and unreliable, and they utilize packaging volume inefficiently. The proposed CHEM antenna structures would be simple and would deploy themselves without need for any mechanisms and, therefore, would be more reliable. The proposed CHEM antenna structures would also weigh less, could be packaged in smaller volumes, and would cost less, relative to mechanically deployable antennas. The CHEM concept was described in two prior NASA Tech Briefs articles: "Cold Hibernated Elastic Memory (CHEM) Expandable Structures" (NPO-20394), Vol. 23, No. 2 (February 1999), page 56; and "Solar Heating for Deployment of Foam Structures" (NPO-20961), Vol. 25, No. 10 (October 2001), page 36. To recapitulate from the cited prior articles: The CHEM concept is one of utilizing opencell foams of shape-memory polymers (SMPs) to make lightweight, reliable, simple, and inexpensive structures that can be alternately (1) compressed and stowed compactly or (2) expanded, then rigidified for use. A CHEM structure is fabricated at full size from a block of SMP foam in its glassy state [at a temperature below the glass-transition temperature (Tg) of the SMP]. The structure is heated to the rubbery state of the SMP (that is, to a temperature above Tg) and compacted to a small volume. After compaction, the structure is cooled to the glassy state of the SMP. The compacting force can then be released and the structure remains compact as long as the temperature is kept below Tg. Upon subsequent heating of the structure above Tg, the simultaneous elastic recovery of the foam and its shape-memory effect cause the structure to expand to its original size and shape. Once thus deployed, the structure can be rigidified by cooling below Tg. Once deployed and rigidified, the structure could be heated and recompacted. In principle, there should be no limit on the achievable number of compaction/deployment/ rigidification cycles. Thus far, several different designs of a 3.5-m-long CHEM conical corrugated horn antenna have been analyzed (see figure). A small CHEM structural antenna model was fabricated and a thin, electrically conductive layer of aluminum was deposited on the inner surface of the model. This structural model was then subjected to the compaction and deployment treatments described above to demonstrate the feasibility of a CHEM corrugated horn antenna.

Sokolowski, Witold↗

NASA NTRS2012

Structures and Mechanisms Design Concepts for Adaptive Deployable Entry Placement Technology

System studies have shown that large deployable aerodynamic decelerators such as the Adaptive Deployable Entry and Placement Technology (ADEPT) concept can revolutionize future robotic and human exploration missions involving atmospheric entry, descent and landing by significantly reducing the maximum heating rate, total heat load, and deceleration loads experienced by the spacecraft during entry [1-3]. ADEPT and the Hypersonic Inflatable Aerodynamic Decelerator (HIAD) [4] share the approach of stowing the entry system in the shroud of the launch vehicle and deploying it to a much larger diameter prior to entry. The ADEPT concept provides a low ballistic coefficient for planetary entry by employing an umbrella-like deployable structure consisting of ribs, struts and a fabric cover that form an aerodynamic decelerator capable of undergoing hypersonic flight. The ADEPT "skin" is a 3-D woven carbon cloth that serves as a thermal protection system (TPS) and as a structural surface that transfers aerodynamic forces to the underlying ribs [5]. This paper focuses on design activities associated with integrating ADEPT components (cloth, ribs, struts and mechanisms) into a system that can function across all configurations and environments of a typical mission concept: stowed during launch, in-space deployment, entry, descent, parachute deployment and separation from the landing payload. The baseline structures and mechanisms were selected via trade studies conducted during the summer and fall of 2012. They are now being incorporated into the design of a ground test article (GTA) that will be fabricated in 2013. It will be used to evaluate retention of the stowed configuration in a launch environment, mechanism operation for release, deployment and locking, and static strength of the deployed decelerator. Of particular interest are the carbon cloth interfaces, underlying hot structure, (Advanced Carbon- Carbon ribs) and other structural components (nose cap, struts, and main body) designed to withstand the pressure and extremely high heating experienced during planetary entry.

Yount, Bryan C.↗

NASA NTRS2014

Mechanism Design and Testing of a Self-Deploying Structure Using Flexible Composite Tape Springs

The detailed mechanical design of a novel deployable support structure that positions and tensions a membrane optic for space imagining applications is presented. This is a complex three-dimensional deployment using freely deploying rollable composite tape spring booms that become load bearing structural members at full deployment. The deployment tests successfully demonstrate a new architecture based on rolled and freely deployed composite tape spring members that achieve simultaneous deployment without mechanical synchronization. Proper design of the flexible component mounting interface and constraint systems, which were critical in achieving a functioning unit, are described. These flexible composite components have much potential for advancing the state of the art in deployable structures, but have yet to be widely adopted. This paper demonstrates the feasibility and advantages of implementing flexible composite components, including the design details on how to integrate with required traditional mechanisms.

Footdale, Joseph N.↗

NASA NTRS2013

Accommodating Thickness in Origami-Based Deployable Arrays

The purpose of this work is to create deployment systems with a large ratio of stowed-to-deployed diameter. Deployment from a compact form to a final flat state can be achieved through origami-inspired folding of panels. There are many models capable of this motion when folded in a material with negligible thickness; however, when the application requires the folding of thick, rigid panels, attention must be paid to the effect of material thickness not only on the final folded state, but also during the folding motion (i.e., the panels must not be required to flex to attain the final folded form). The objective is to develop new methods for deployment from a compact folded form to a large circular array (or other final form). This paper describes a mathematical model for modifying the pattern to accommodate material thickness in the context of the design, modeling, and testing of a deployable system inspired by an origami six-sided flasher model. The model is demonstrated in hardware as a 1/20th scale prototype of a deployable solar array for space applications. The resulting prototype has a ratio of stowed-to-deployed diameter of 9.2 (or 1.25 m deployed outer diameter to 0.136 m stowed outer diameter).

flasher↗

NASA NTRS2019

Electric Sail Tether Deployment System for CubeSats

An Electric Sail (E-Sail) propulsion system consists of long, thin tethers - positively-charged wires extending radially and symmetrically outward from a spacecraft. Tethers must be biased using a high-voltage power supply to ensure that the solar wind produces thrust. While the E-Sail concept shows great promise for flying heliopause missions with higher characteristic acceleration than solar sails, there are significant technical challenges related to deploying and controlling multiple tethers. A typical full-scale design involves a hub and spoke arrangement of 10 to 100 tethers, each 20 km long. In the last 20 years, there have been multiple space mission failures due to tether deployment and control issues, and most configurations involved a single tether. This paper describes an effort to develop and test a simple yet robust single-tether deployment system for a two-6U CubeSat configuration. The project included the following: a) Tether dynamic modeling/simulation b) E-Sail single-tether prototype development and testing c) Space environmental effects testing to identify best materials for further development. These three areas of investigation were needed to provide technical rationale for an E-Sail flight demonstration mission that is expected to be proposed for the 2022 time frame. The project team used an “agile” engineering approach in which E-Sail single-tether prototype designs were iteratively developed and tested to solve problems and identify design improvements. The agile approach was ideal for this low Technology Readiness Level (TRL) project because tether deployer development involved many unknowns in prototype development that could only be discovered through iterative cycles of construction and testing. Extensive modeling and simulation were accomplished for three types of tether deployment: a) Stage 1: propulsive separation with one 6U fixed b) Stage 2: propulsive spin-up with one 6U fixed c) Stage 3: propulsive spin-up with both 6Us free Simulation results were valuable for understanding the propulsive and braking forces needed for controlled tether deployment. This paper describes the evolution, insights, and test/ performance data related to the resultant single-tether two-6U E-Sail test article which has been demonstrated in a test laboratory. The development effort suggests near-term work needed to achieve a useful flight demonstration, and provides ideas for how multiple-tether deployment systems might evolve going forward. A planned next-generation E-Sail prototype will include autonomous propulsive tether deployment while monitoring tether tension, location on the floor, distance between tether ends, acceleration, velocity, and propellant used.

Tinker, Michael↗

NASA NTRSDate not supplied

A Multifunctional Bistable Ultrathin Composite Boom for In-Space Monitoring of Deployment Dynamics

A novel concept of a multifunctional deployable ultrathin composite boom with flexible electronics and circuits integrated in a highly compact configuration, which can monitor its deployment dynamics in space, is presented in this paper. This concept is particularly suitable for CubeSats with extremely limited payload volume. The multifunctional deployable boom will be flight hardware installed in a 3U CubeSat that is scheduled to be launched to the International Space Station (ISS) in 2023 as an in-space technology demonstration. The multifunctional boom consists of a bistable self-deployable ultrathin composite boom, flexible electronics and circuitry for dynamics monitoring, and embedded flexible thin wires for power delivery and data transmission. The design, materials, and fabrication methods for the multifunctional boom are presented. Tests in simulated space environments showed the survivability and stability of the flexible electronics within a temperature range of 7 °C to 50 °C and under a high vacuum level of approximately 1 × 10−6 Torr. Ground-based vibration and deployment tests demonstrated the overall design of the multifunctional boom, data acquisition system, and deployment mechanism. Analyses of the data obtained from the integrated flexible electronics successfully captured the deployment dynamics and identified the natural frequencies of the boom in the range of 0–100 Hz. These results demonstrate that the concept is a promising approach to future multifunctional ultrathin deployable space structures.

Yao Yao↗

NASA NTRSDate not supplied

A Multifunctional Bistable Ultrathin Composite Boom for In-Space Monitoring of Deployment Dynamics

Yao Yao↗

NASA NTRS2022

SWOT and NISAR Boom Ground Deployment Test Challenges & Resolution

NASA’s Jet Propulsion Laboratory is developing two new spacecraft that use radar instruments to characterize temporal changes in the Earth’s surface with unprecedented precision (Figure 1). Both the Surface Water Ocean Topography (SWOT) and the NASA-ISRO Synthetic Aperture Radar (NISAR) spacecraft utilize large, precision flight deployable booms to properly position and support their instrument reflectors. The SWOT spacecraft includes two nearly identical reflector booms, each of which have similar flight deployable hinge designs. The NISAR spacecraft has a single reflector boom, with four unique hinge designs. These booms each undergo a multi-staged flight deployment sequence on orbit to transition from the launch stowed configuration to the science configuration within days of launch (Figure 2). The SWOT and NISAR Projects faced significant challenges relevant to requirement verification as well as hardware safety in their approach to ground testing these large flight deployables. This report summarizes flight deployable system design decisions that contributed to ground testing challenges. The report also summarizes the architecture trade study conducted for ground deployment testing. A summary of key issues encountered during flight deployable ground testing with the chosen common gravity offload system ensues, with discussion of the issues and mitigation measures implemented by both Projects that ultimately enabled successful flight subsystem-level full range of motion ground tests. Recommendations and lessons learned are offered to facilitate ground testability of future analogous large scale flight deployables.

Waters, Kyle C.↗

NASA NTRS2006

MARSIS antenna flight deployment anomaly and resolution

This paper summarizes the resolution of an in flight anomaly that occurred during the deployment of the first of three MARSIS antenna booms. Characteristics of this deployment are described, along with a correlation to finite element models and measured spacecraft inertias, which allowed the intermediate state of the boom to be accurately determined. Based on this information, a spacecraft maneuver was performed that warmed the stalled hinge and led to the first boom successfully locking into its designed geometry. The confirmed partially deployed boom shape was then used to develop a thermal model of the stalled hinge both in its initial solar attitude and during the successful spacecraft maneuver. Results from the hinge thermal model and component level testing were evaluated in order to determine the root cause of the anomaly and the probability of its recurrence on subsequent deployments. These conclusions were then utilized in planning mitigating actions that were implemented during the remaining two boom deployments. Final flight data are presented for both dipole booms indicating a correctly deployed and healthy antenna. The monopole boom deployment was detected but the final state of the boom is unknown.

Mars↗