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NASA NTRS1978

Overview of the large space systems technology program

A multicenter management approach which provides the opportunity to work across many disciplines and match the roles and expertise of various NASA facilities is described for the large space system technology (LSST) program which was established to define, develop, and verify structural concepts, analyses, and design procedures for a range of sizes and configurations to be deployed, erected, or fabricated in orbit during projected space missions utilizing shuttle in the 1985 to 2000 time period. Benefits from the program include reduced costs for transporting structures having low mass, high packageability, and multimission capabilities. Technologies identified by the LSST program will contribute to the solutions of problems in other sectors of the economy.

Guastaferro, A.↗

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 NTRS1983

Technical issues in dynamics and control of large space structures

Examples of large space systems currently being considered by NASA include a large communications antenna system (the Land Mobile Satellite System), a precision antenna system (the Large Deployable Reflector System), and a preliminary concept for NASA's space station. Each system has low natural vibration frequencies, stringent pointing requirements, and, for the antennas, demanding surface accuracy requirements. A review is provided of the progress being made in structural ground tests with respect to surface accuracy, deployment, and erection of large structures. Attention is given to the dynamic loads on large space structures, on-orbit testing, space vibration control devices, and the characteristics of distributed control.

Card, M. F.↗

NASA NTRS1988

Space truss construction studies

The ACCESS Shuttle Flight Experiment, designed to evaluate EVA for on-orbit assembly of erectable truss structure, is reviewed and principal results are summarized. In addition, two on-going ground test programs that address EVA assembly of full scale Space Station truss structure using a mobile transporter are described. A typical truss joint design that enables EVA assembly while satisfying structural requirements is also presented. Preliminary results indicate that assembly rates in excess of one strut/min are achievable.

Heard, Walter L.↗

NASA NTRS1986

Joint for Rapid Structural Assembly

Quickly attaching joint used in variety of truss structures. Split ring made in one piece and split radially after final machining. Mating tapers on split ring and endbells small: approximately 7 degrees. Tapers of this range permit high internal preloads to be obtained, yet parts easily separated when collar released. Results from tests on developmental model indicate load-displacement response linear and substantial preloading accomplished. Quickly-erecting truss structures have variety of applications, from Earth to space-station keel beams, antenna masts, and large platforms.

Rhodes, M. D.↗

NASA NTRS1993

Modal parameters of space structures in 1 G and 0 G

Analytic and experimental results are presented from a study of the changes in the modal parameters of space structural test articles from one- to zero-gravity. Deployable, erectable, and rotary modules was assembled to form three one- and two-dimensional structures, in which variations in bracing wire and rotary joint preload could be introduced. The structures were modeled as if hanging from a suspension system in one gravity, and unconstrained, as if free floating in zero-gravity. The analysis is compared with ground experimental measurements, which were made on a spring-wire suspension system with a nominal plunge frequency of one Hertz, and with measurements made on the Shuttle middeck. The degree of change in linear modal parameters as well as the change in nonlinear nature of the response is examined. Trends in modal parameters are presented as a function of force amplitude, joint preload, reassembly, shipset, suspension, and ambient gravity level.

Bicos, Andrew S.↗

NASA NTRS2004

Lightweight Deployable Mirrors with Tensegrity Supports

The upper part of Figure 1 shows a small-scale prototype of a developmental class of lightweight, deployable structures that would support panels in precise alignments. In this case, the panel is hexagonal and supports disks that represent segments of a primary mirror of a large telescope. The lower part of Figure 1 shows a complete conceptual structure containing multiple hexagonal panels that hold mirror segments. The structures of this class are of the tensegrity type, which was invented five decades ago by artist Kenneth Snelson. A tensegrity structure consists of momentfree compression members (struts) and tension members (cables). The structures of this particular developmental class are intended primarily as means to erect large segmented primary mirrors of astronomical telescopes or large radio antennas in outer space. Other classes of tensegrity structures could also be designed for terrestrial use as towers, masts, and supports for general structural panels. An important product of the present development effort is the engineering practice of building a lightweight, deployable structure as an assembly of tensegrity modules like the one shown in Figure 2. This module comprises two octahedral tensegrity subunits that are mirror images of each other joined at their plane of mirror symmetry. In this case, the plane of mirror symmetry is both the upper plane of the lower subunit and the lower plane of the upper subunit, and is delineated by the midheight triangle in Figure 2. In the configuration assumed by the module to balance static forces under mild loading, the upper and lower planes of each sub-unit are rotated about 30 , relative to each other, about the long (vertical) axis of the structure. Larger structures can be assembled by joining multiple modules like this one at their sides or ends. When the module is compressed axially (vertically), the first-order effect is an increase in the rotation angle, but by virtue of the mirror arrangement, the net first-order rotation between the uppermost and lowermost planes is zero. The need to have zero net rotation between these planes under all loading conditions in a typical practical structure is what prompts the use of the mirror configuration. Force and moment loadings other than simple axial compression produce only second-order deformations through strains in the struts and cables.

Zeiders, Glenn W.↗

NASA NTRS1991

Structural load control during construction

In the absence of gravitational pull, the major design considerations for large space structures are stiffness for controllability, and transient dynamic loadings (as opposed to the traditional static load associated with earth-based structures). Because of the absence of gravitational loading, space structures can be designed to be significantly lighter than their counterparts on Earth. For example, the Space Shuttle manipulator arm is capable of moving and positioning a 60,000 lb payload, yet weighs less than 1,000 lbs. A recent design for the Space Station which had a total weight of about 500,000 lbs. used a primary loadcarrying keel beam which weighed less than 10,000 lbs. For many large space structures designs it is quite common for the load-carrying structure to have a mass fraction on the order of one or two percent of the total spacecraft mass. This significant weight reduction for large space structures is commonly accompanied by very low natural frequencies. These low frequencies cause an unprecedented level of operational complexity for mission applications which require a high level of positioning and control accuracy. This control problem is currently the subject of considerable research directed towards reducing the flexibility problem. In addition, however, the small mass fraction typically results in structures which are quite unforgiving to inadvertent high loadings. In other words, the structures are 'fragile.' In order to deal with the fragility issue CSC developed a load-limiting concept for space truss structures. This concept is aimed at limiting the levels of load which can occur in a large space structure during the construction process as well as during subsequent operations. Currently, the approach for dealing with large loadings is to make the structure larger. The impact this has on construction is significant. The larger structures are more difficult to package in the launch vehicle, and in fact in some instances the concept must be changed from a deployable truss to an erectable truss to permit packaging. The new load-limiting concept is aimed at permitting the use in large space structures of smaller trusses with a high level of strength robustness, in order to simplify the construction process. To date several analyses conducted on the concept have demonstrated its feasibility, and an experiment is currently being designed to demonstrate its operation.

Mikulas, Martin M., Jr.↗

NASA NTRS1992

Variation in the modal parameters of space structures

An analytic and experimental study of gravity and suspension influences on space structural test articles is presented. A modular test article including deployable, erectable, and rotary modules was assembled in three one- and two-dimensional structures. The two deployable modules utilized cable diagonal bracing rather than rigid cross members; within a bay of one of the deployable modules, the cable preload was adjustable. A friction lock was used on the alpha joint to either allow or prohibit rotary motion. Suspension systems with plunge fundamentals of 1, 2, and 5 Hz were used for ground testing to evaluate the influences of suspension stiffness. Assembly and reassembly testing was performed, as was testing on two separate shipsets at two test sites. Trends and statistical variances in modal parameters are presented as a function of force amplitude, joint preload, reassembly, shipset and suspension. Linear finite element modeling of each structure provided analytical results for 0-g unsuspended and 1-g suspended models, which are correlated with the analytical model.

Crawley, Edward F.↗

NASA NTRS1992

Spacecraft dynamics characterization and control system failure detection, volume 1

The work under this grant has been directed to two aspects of the control of flexible spacecraft: (1) the modeling of deployed or erected structures including nonlinear joint characteristics; and (2) the detection and isolation of failures of the components of control systems for large space structures. The motivation for the first of these research tasks is the fact that very large assemblies in space will have to be built or deployed in situ. A likely scenario is, in fact, a combination of these wherein modules which are folded for transportation into orbit are erected to their final configuration and then jointed with other such erected modules to form the full assembly. Any such erectable modules will have joints. It remains to be seen whether or not joints designed for operational assemblies will have nonlinear properties, but it seems prudent to develop a methodology for dealing with that possibility. The motivation for the second of these research tasks is the fact that we foresee large assemblies in space which will require active control to damp vibrations and/or hold a desired shape. Lightweight structures will be very flexible, with many elastic modes having very low frequencies. In order to control these modes well, the control system will likely require many sensors and many actuators, probably distributed over much of the structure. The combination of a large number of control system components with long operational periods virtually guarantees that these systems will suffer control system component failures during operation. The control system must be designed to tolerate failures of some sensors and actuators, and still be able to continue to perform its function.

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NASA NTRS1992

Middeck zero-gravity dynamics experiment - Comparison of ground and flight test data

An analytic and experimental study of the changes in the modal parameters of space structural test articles from one- to zero-gravity is presented. Deployable, erectable, and rotary modules was assembled to form three one- and two-dimensional structures, in which variations in bracing wire and rotary joint preload could be introduced. The structures were modeled as if hanging from a suspension system in one gravity, and unconstrained, as if free floating in zero-gravity. The analysis is compared with ground experimental measurements, made on a spring/wire suspension system with a nominal plunge frequency of one Hertz, and with measurements made on the Shuttle middeck. The degree of change in linear modal parameters as well as the change in nonlinear nature of the response is examined. Trends in modal parameters are presented as a function of force amplitude, joint preload, and ambient gravity level.

Crawley, Edward F.↗

NASA NTRS1980

Space assembly fixtures and aids

Concepts and requirements for assembly fixtures and aids necessary for the assembly and maintenance of spare platforms were studied. Emphasis was placed on erectable and deployable type structures with the shuttle orbiter as the assembly base. Both single and multiple orbiter flight cases for the platform assembly were considered. Applicable space platform assembly studies were reviewed to provide a data base for establishing the assembly fixture and aids design requirements, assembly constraints, and the development of representative design concepts. Conclusions indicated that fixture requirements will vary with platform size. Larger platforms will require translation relative to the orbiter RMS working volume. The installation of platform payloads and subsystems (e.g., utility distribution) must also be considered in the specification of assembly fixtures and aids.

Bloom, K. A.↗

NASA NTRS1988

A 60-meter erectable assembly concept for a control of flexible structures flight experiment

A flight experiment which proposes to use a 60-m deployable/retractable truss beam attached to the Space Shuttle to study dynamic characterization and control of flexible structures is being studied by NASA. The concept requires a relatively complex mechanism for deploying and retracting the truss on-orbit. Development of such a mechanism having a high degree of reliability will be expensive. An alternative method for constructing the truss is discussed requiring no new technology development or complex mechanisms and has already been demonstrated on-orbit. The alternative method proposes an erectable truss beam which can be assembled by two astronauts in EVA. The EVA crew would have to manually assemble the beam from 468 struts and 165 nodes, and install 7 instrumentation platforms with signal and power cabling. The predicted assembly time is 3 hr and 23 min. The structure would also have to be disassembled and restowed following testing, thus 2 EVA days would be required. To allow 25 hr for data collection (probably a bare minimum to accomplish meaningful tests), current Shuttle operations policy dictates a 9-day mission. The design, assembly procedure and issues associated with the alternative concept are discussed.

Watson, Judith J.↗

NASA NTRS1976

Collapsible Towers

NASA needed a means of orbiting a large radio telescope antenna. Astro Research Corporation developed a new structure that was strong, lightweight, folded into a small storage space, and could be erected by rotation. Later they adapted it to commercial use. Today the "Astromast" tower consists of tubular aluminum alloy and stainless steel members that deploy into small three-sided bays, each made rigid by six diagonal cables. All joints are flexible to permit folding and unfolding. Tower packs into container 5% of its height, can be erected without tools and is reusable. Tower has won "Design of the Year" award from Machine Design. Variations include portable emergency bridges and commercial scaffolding.

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NASA NTRS1978

Structural/thermal considerations for design of large space platform structures

A method is described for placing a large, STS-compatible platform on orbit utilizing a construction method employing both deployable and erectable structures. A multifunctional mechanism is used for deployable structures and an on-orbit assembly is used for erectable structures. Also analyses are discussed which assess the thermal distortion of a simple open truss and a more complex truss.

Barclay, D. L.↗

NASA NTRS1980

A mechanical adapter for installing mission equipment on large space structures

A mechanical attachment adapter was designed, constructed, and tested. The adapter was was included in a simulation program that investigated techniques for assembling erectable structures under simulated zero-g conditions by pressure-suited subjects in a simulated EVA mode. The adapter was utilized as an interface attachment between a simulated equipment module and one node point of a tetrahedral structural cell. The mating performance of the adapter, a self-energized mechanism, was easily and quickly demonstrated and required little effort on the part of the test subjects.

Lefever, A. E.↗

NASA NTRS1984

Preliminary space station solar array structural design study

Structurally efficient ways to support the large solar arrays (3,716 square meters which are currently considered for space station use) are examined. An erectable truss concept is presented for the on orbit construction of winged solar arrays. The means for future growth, maintenance, and repair are integrally designed into this concept. Results from parametric studies, which highlight the physical and structural differences between various configuration options are presented. Consideration is given to both solar blanket and hard panel arrays.

Dorsey, J. T.↗

NASA NTRS1980

Structural sizing considerations for large space platforms

Structural optimization studies are made using mathematical programming techniques to examine minimum mass structural proportions of deployable and erectable tetrahedral truss platforms subject to the integrated effects of practical design requirements. Considerations integrated into the optimization process are: 1) lowest natural frequencies of the platform and individual platform components (struts); 2) packaging constraints imposed by the Shuttle cargo bay capacity; 3) initial curvature of the struts; 4) column buckling of the struts due to gravity gradient, orbital transfer, strut length tolerance, or design loads; and 5) practical lower limits for strut diameter and wall thickness. Ultra-low mass designs are shown to be possible with strut proportions much more slender than those conventionally used for earthbound application.

Heard, W. L., Jr.↗