Full Scale Flat Floor Testing of a 500-M2-Class Solar Sail Deployer
Solar sailing missions rely on deployable systemsfor large area to mass ratios once in space, whilestill being small enough for launcher envelopes inthe stowed configuration. Many of thesedeployable systems feature booms that areflattened and subsequently coiled onto aspool/hub. As part of a collaborative deployablespace structures research effort of NASA and DLR,a boom deployment mechanism for a future 500 m²solar sail has been developed since 2017. To achieve the respective solar sail size goal, 16.5m long booms produced by NASA were integratedinto a DLR-designed deployer mechanism. Thisconsiderable size, as well as the lightweightconstruction of the booms and respectivedeployable systems makes ground testing asignificant challenge. Some systems for gravitycompensation and boom alignment will bepresented in the paper. However, the main focus isthe functional flat floor testing of the integratedboom-deployment mechanism system, as well asits challenges. The testing performed includes full deployment aswell as stowage of the booms. Both have beenperformed multiple times. The latter is one of thekey parameters determining packaging efficiency,which in turn confirms design assumptions. Duringsystem development, small scale tests and modelshave been used in preparation of flat floor testingof the 33 m span cross of the full-scale booms anddeployment mechanism. Hence a small chapter isalso devoted to analysing the differences inbehaviour between small- and full-scaledeployment systems. More parameters that are vital to design decisionshave been determined this way, such as drivingbelt force or hub brake torque. This paper alsofocuses on development goals and needs forfuture steps to achieve higher levels of technologyreadiness, such as the balancing of driving motorforce, synchronisation of its transmission and thecountering hub brake torque