Stress Relaxation of Carbon Fiber Composites for Deployable Space Structures
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Jonathan Cruz↗
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On-Orbit Investigation of Transient Microdynamic Disturbances on a Deployed Truss Structure
The second Interferometry Program Experiment (IPEX-2) is a technology demonstration precursor to the Space Interferometry Mission, a 10-meter baseline space-based interferometer scheduled for launch in 2005.
Flight↗
Design and Testing of the BionicWingSat in a Zero-g Flight Campaign - A 2U-CubeSat with Deployable, Biologically-Inspired Wings
In this paper, recent developments in the design, manufacturing, and testing of a novel deployable structure with several potential applications in space will be described. Through a cooperative effort of the German Aerospace Center (DLR) and the National Aeronautics and Space Administration (NASA), a biologically inspired structurally integrated membrane featuring distributed functional elements has been developed and tested in a 2U CubeSat called BionicWingSat. Such a membrane structure could be useful for several applications in which a relatively flat area is desirable such as solar sails, drag sails, or solar shades. For SmallSats and CubeSats, the design proposed also has the desirable property of being self-deploying without the need for powered deployment mechanisms. Building on previous work inspired by the wings of earwigs, the research presented in this paper includes structural design of self-deploying hinges, a survey of various advanced additive layer manufacturing (ALM) methods for making hinges, mechanical characterization of the hinges, and finite element analysis (FEA) of the hinges. In this work, the conflicting goals of maximizing deployed structural stiffness, maximizing deployed area, maximizing stowed packaging efficiency, and maximizing resistance to creep when stowed must be considered. The resulting design concept is a gossamer structure that cannot support its own weight in gravity. For this reason, a focus in this paper is on a parabolic flight test campaign in which 24 fully integrated wings on two BionicWingSats were tested in a microgravity environment. From this test campaign, several lessons were learned regarding the wing design and procedures for carrying out microgravity tests of this manner.
CubeSat↗
Design and Testing of the BionicWingSat in a Zero-g Flight Campaign - A 2U-CubeSat with Deployable, Biologically-Inspired Wings
In this paper, recent developments in the design, manufacturing, and testing of a novel deployable structure with several potential applications in space will be described. Through a cooperative effort of the German Aerospace Center (DLR) and the National Aeronautics and Space Administration (NASA), a biologically inspired structurally integrated membrane featuring distributed functional elements has been developed and tested in a 2U CubeSat called BionicWingSat. Such a membrane structure could be useful for several applications in which a relatively flat area is desirable such as solar sails, drag sails, or solar shades. For SmallSats and CubeSats, the design proposed also has the desirable property of being self-deploying without the need for powered deployment mechanisms. Building on previous work inspired by the wings of earwigs, the research presented in this paper includes structural design of self-deploying hinges, a survey of various advanced additive layer manufacturing (ALM) methods for making hinges, mechanical characterization of the hinges, and finite element analysis (FEA) of the hinges. In this work, the conflicting goals of maximizing deployed structural stiffness, maximizing deployed area, maximizing stowed packaging efficiency, and maximizing resistance to creep when stowed must be considered. The resulting design concept is a gossamer structure that cannot support its own weight in gravity. For this reason, a focus in this paper is on a parabolic flight test campaign in which 24 fully integrated wings on two BionicWingSats were tested in a microgravity environment. From this test campaign, several lessons were learned regarding the wing design and procedures for carrying out microgravity tests of this manner.
CubeSat↗
Deployable Temporary Shelter
Compact storable components expand to create large shelter. Fully deployed structure provides large, unobstructed bay. Deployed trusses support wall and roof blankets. Provides temporary cover for vehicles, people, and materials. Terrestrial version used as garage, hangar, or large tent.
Shaffer, Joe R.↗
Imaging Dot Patterns for Measuring Gossamer Space Structures
A paper describes a photogrammetric method for measuring the changing shape of a gossamer (membrane) structure deployed in outer space. Such a structure is typified by a solar sail comprising a transparent polymeric membrane aluminized on its Sun-facing side and coated black on the opposite side. Unlike some prior photogrammetric methods, this method does not require an artificial light source or the attachment of retroreflectors to the gossamer structure. In a basic version of the method, the membrane contains a fluorescent dye, and the front and back coats are removed in matching patterns of dots. The dye in the dots absorbs some sunlight and fluoresces at a longer wavelength in all directions, thereby enabling acquisition of high-contrast images from almost any viewing angle. The fluorescent dots are observed by one or more electronic camera(s) on the Sun side, the shade side, or both sides. Filters that pass the fluorescent light and suppress most of the solar spectrum are placed in front of the camera(s) to increase the contrast of the dots against the background. The dot image(s) in the camera(s) are digitized, then processed by use of commercially available photogrammetric software.
Dorrington, A. A.↗
Toggle Hinge for Deployable Struts
Toggle hinge allows deployable structures erected without end play encountered in conventional hinged structural members. New hinge ensures rigidity in portable bridges, masts, towers, platforms, and other deployable (and retractable) structures. Positioned halfway along length of folding strut, hinge allows halves of strut to pivot 180 degrees about center.
Barbour, R. T.↗
Segmented Solid Surface Reflector Concentrically Stacked With Tubular Shape Memory Composite Hinges
A new architecture for solid surface reflector antennas scalable to sizes greater than 10 m is presented. The design uses compact, light, and simple advanced deployable structures to create sub-reflectors that can be assembled in space into larger units using a robotic arm. The seven-panel hexagonal sub-reflector is divided into hexagonal panels that stack concentrically and vertically. The central panel is connected to each side panel on the back side by a pair of tubular shape memory composite hinges that enable the required deployment kinematics with controlled dynamics. A secondary mechanism closes the interpanel gap. The focus of the paper is on the development of the sub-reflector elements, namely the tubular hinges that use embedded heaters and sensors for triggering and control, the actuation mechanisms, and the lightweight sandwich construction reflector panels. A parametric study using finite element analyses was conducted to assess how design features of the hinge affect its stowage and deployment dynamics. The preliminary component fabrication and testing results for the two-panel assembly breadboard model are outlined. Finally, the results of the test campaign with the brassboard reflector model are presented. A comparison of deployed reflector surface deviation between the measured surface after the stowage and deployment process and the pre-test scans and the nominal surface revealed root mean square errors of less than 1 mm, as required by X-band radiofrequency transmission.
gravity offloading↗
Segmented Hexagonal Antenna Reflector Concentrically Stacked Using Shape Memory Composite Tubular Hinges
A new architecture for solid surface reflector antennas scalable to sizes greater than 10 m is presented. The design uses compact, light, and simple advanced deployable structures to create sub-reflectors that can be assembled in space into larger units using a robotic arm. The seven-panel hexagonal sub-reflector is divided into hexagonal panels that stack concentrically and vertically. The central panel is connected to each side panel on the back side by a pair of tubular shape memory composite hinges that enable the required deployment kinematics with controlled dynamics. A secondary mechanism closes the interpanel gap. The focus of the paper is on the development of the sub-reflector elements, namely the tubular hinges that use embedded heaters and sensors for triggering and control, the actuation mechanisms, and the lightweight sandwich construction reflector panels. A parametric study using finite element analyses was conducted to assess how design features of the hinge affect its stowage and deployment dynamics. The preliminary component fabrication and testing results for the two-panel assembly breadboard model are outlined. Finally, the results of the test campaign with the brassboard reflector model are presented. A comparison of deployed reflector surface deviation between the measured surface after the stowage and deployment process and the pre-test scans and the nominal surface revealed root mean square errors of less than 1 mm, as required by X-band radiofrequency transmission.
gravity offloading methods↗
NASA's Advanced Solar Sail Propulsion System for Low-Cost Deep Space Exploration and Science Missions that Use High Performance Rollable Composite Booms
Several low-cost solar sail technology demonstrator missions are under development in the United States. However, the mass saving derived benefits that composites can offer to such a mass critical spacecraft architecture have not been realized yet. This is due to the lack of suitable composite booms that can fit inside CubeSat platforms and ultimately be readily scalable to much larger sizes, where they can fully optimize their use. With this aim, a new effort focused at developing scalable rollable composite booms for solar sails and other deployable structures has begun. Seven meter booms used to deploy a 90 m2 class solar sail that can fit inside a 6U CubeSat have already been developed. The NASA road map to low-cost solar sail capability demonstration envisioned, consists of increasing the size of these composite booms to enable sailcrafts with a reflective area of up to 2000 m2 housed aboard small satellite platforms. This paper presents a solar sail system initially conceived to serve as a risk reduction alternative to Near Earth Asteroid (NEA) Scout's baseline design but that has recently been slightly redesigned and proposed for follow-on missions. The features of the booms and various deployment mechanisms for the booms and sail, as well as ground support equipment used during testing, are introduced. The results of structural analyses predict the performance of the system under microgravity conditions. Finally, the results of the functional and environmental testing campaign carried out are shown.
Fernandez, Juan M.↗
Weight estimates and packaging techniques for the microwave radiometer spacecraft
Estimates of total spacecraft weight and packaging options were made for three conceptual designs of a microwave radiometer spacecraft. Erectable structures were found to be slightly lighter than deployable structures but could be packaged in one-tenth the volume. The tension rim concept, an unconventional design approach, was found to be the lightest and transportable to orbit in the least number of shuttle flights.
Jensen, J. K.↗
Epoxy Resins with Reduced Viscoelastic Relaxation
The payloads of current space launch systems, e.g. rockets, are constrained to a small size due to aerodynamic, weight, and cost limitations. Deployable structures allow for a folded or stowed configuration during launch and deployment at the mission location. Polymer composites have shown both high weight savings over current metallic structure, as well as improved specific mechanical strengths overall. One issue encountered with polymer composite deployables, however, is stress relaxation of the polymer matrix in the stowed configuration. In this study, a range of different epoxy formulations were evaluated as potential matrix resins for deployable composites. A new multifunctional epoxy resin with a fortifying additive is predicted to show 70% less stress relaxation after 1 year as compared to a state-of-the-art aerospace epoxy matrix.
Ray S. Peterson↗
Using ERF Devices to Control Deployments of Space Structures
A report proposes devices containing electrorheological fluids (ERFs) damper for controlling deployments of lightweight, flexible structures in outer space. The structures would include spring members that could be wound or compressed for compact stowage during transport. The ERF based damper would keep the structures compacted and/or regulate the speeds with which the structures would spring out for deployment. After deployment, ERF based dampening mechanism could be used to rigidize the structures or damp their vibrations. An experimental ERF deployment controlled structure described in the report comprised two metal carpenter s measuring tapes sandwiched together, held slightly apart by rubber-band spacers, and placed in a bag filled with an ERF. The viscosity of the ERF varied with the voltage applied to the tapes, such that it was possible to hold the tapes in the wound condition or slow the speed with which they sprung from the wound to the straight condition. The report describes several potential variations on the basic concept of an ERF-controlled structural member, including compartmentalization of the interior volume to prevent total loss of the ERF in case of a leak and the use of multiple, individually addressable electrode pairs to enable more localized control.
Bar-Cohen, Yoseph↗
Blanket technology workshop report
The solar array blanket, defined as a substrate covered with interconnected and glassed solar cells, but excluding the necessary support structure, deployment, and orientation devices is considered. The interactions between the blanket and the structure that is used to package, deploy, support and, if necessary restow it, are addressed along with systems constraints such as spacecraft configuration, size, and payload requirements. The influence on blanket design is emphasized. The three main mission classes considered are low Earth orbital (LEO), intermediate, or LEO to GEO transfer, and geosynchronous (GEO). Although interplanetary missions could be considered to be a separate class, their requirements, primarily power per unit mass, are generally close enough to geosynchronous missions to allow this mission class to be included within the third type. Examination of the critical elements of each class coupled with considerations of the shuttle capabilities is used to define the type of blanket technology most likely required to support missions that will be flown starting in 1990.
Scott-Monck, J. A.↗