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NASA NTRS2004

Co-axial Joint Technology Applied to Antenna Backup Structures

The increasing demand to improve focusing accuracy and to accommodate higher frequencies in space communications and radio astronomy has created significant challenges for improving the capability of the constituent systems in radio antennas and telescopes. One important system is the radio antenna/telescope backup structure connections. The backup structure is a key element in providing a stable, precise and rigid support for the reflective surface. The ideal connection for these types of structures is rigid and concentric resulting in minimal deformation with stress/strain curves that are linear, repeatable and exhibiting no hysteresis over the entire service load range. Conceivably such a connection could be designed so that the stress/strain curve mimics the stress/strain characteristics of the connecting member in both tension and compression. When this is achieved then such joints can be said to be 'invisible' in the global behavior of the backup structure. At that point, overall reflector deflection becomes more linear and highly predictable. In conjunction with this advantage, optimized backup structure geometries, adaptive reflectors and compensating algorithms can best be applied in producing an instrument of unparalleled performance. This paper introduces Co-Axial Joint (CAJ) technology as the practical and economical means to produce an invisible connection.

trusses↗

NASA NTRS1989

Vibration suppression for precision segmented reflector backup structure

An ongoing effort at the JPL on vibration suppression for the Precision Segmented Reflector backup structure is centered on the vibration damping augmentation through a system consisting of active and passive damping members. An active member is a structural member with built-in piezoelectric actuator and sensors. An efficient method was developed for optimal placement of active and passive damping members in the truss-type backup structure. A simple synergistic model between the active and passive damping was proposed based on a weighted energy dissipation criterion. A baseline passive member design with constrained viscoelastic material treatment was used as the source of passive damping.

Chen, G.-S.↗

NASA NTRS2005

High-Temperature Polymer Composites Tested for Hypersonic Rocket Combustor Backup Structure

Significant component weight reductions are required to achieve the aggressive thrust-toweight goals for the Rocket Based Combined Cycle (RBCC) third-generation, reusable liquid propellant rocket engine, which is one possible engine for a future single-stage-toorbit vehicle. A collaboration between the NASA Glenn Research Center and Boeing Rocketdyne was formed under the Higher Operating Temperature Propulsion Components (HOTPC) program and, currently, the Ultra-Efficient Engine Technology (UEET) Project to develop carbon-fiber-reinforced high-temperature polymer matrix composites (HTPMCs). This program focused primarily on the combustor backup structure to replace all metallic support components with a much lighter polymer-matrixcomposite- (PMC-) titanium honeycomb sandwich structure.

Sutter, James K.↗

NASA NTRS1982

Thermal analysis of antenna backup structure. Part 1. Methodology development

An analytic method was devised to predict the temperature distribution in typical antenna structural back-up members. The results are in agreement with those obtained by a numerical shooting method. The analytic method shows potential in simplifying the thermal analysis process for complex back-up antenna structures.

Schonfeld, D.↗

NASA NTRS1990

Making Lightweight Structures By Vapor Deposition

Technique developed for fabrication of stiff, strong, lightweight structures of silicon carbide or other materials by any of several deposition processes. Structures made by method can have complicated shapes. Ability to manufacture complex shape from pure deposited SiC useful and leads to new products in several fields. These lightweight structures used as backup structures for optical components, as structural components in automotive, aerospace, and outer space applications, and as lightweight parts of furniture for outer space.

Goela, Jitendra S.↗

NASA NTRS1989

Large scale fabrication of lightweight Si/SiC lidar mirrors

An up-scalable CVD process has been used to fabricate 7.5-cm models of lightweight Si/SiC mirrors consisting of an f/1.6 concave face-plate of SiC coated with CVD Si, in conjunction with a lightweight backup structure of SiC. Due to CVD chamber fabrication, no bonding agent was required to attach the SiC backup structure to the face-plate. Upon up-scaling, the SiC deposition process has been able to produce 40-cm diameter f/1.6 concave mirror face-plates. The mirrors were polished to a 1/5-wave figure and 10 A rms surface finish. There appear to be no intrinsic physical limits to further up-scaling of this mirror-fabrication process.

Goela, Jitendra Singh↗

NASA NTRS1988

Hybrid deployable support truss designs for LDR

Concepts for a 20-meter diameter Large Deployable Reflector (LDR) deployable truss backup structure, and analytical predictions of its structural characteristics are discussed. The concept shown is referred to as the SIXPAC; It is a combination of the PACTRUSS concept and a single-fold beam, which would make up the desired backup structure. One advantage of retaining the PACTRUSS concept is its packaging density and its capability for synchronous deployment. Various 2-meter hexagonal panel arrangements are possible for this Hybrid PACTRUSS structure depending on the panel-to-structure attachment strategies used. Static analyses of the SIXPAC using various assumptions for truss designs and panel masses of 10 kg sq meters were performed to predict the tip displacement of the structure when supported at the center. The tip displacement ranged from 0.20 to 0.44 mm without the panel mass, and from 0.9 to 3.9 mm with the panel mass (in a 1-g field). The data indicate that the structure can be adequately ground tested to validate its required performance in space, assuming the required performance in space is approximately 100 microns. The static displacement at the tip of the structure when subjected to an angular acceleration of 0.001 rad/sec squared were estimated to range from 0.8 to 7.5 microns, depending on the type of truss elements.

Hedgepeth, J.↗

NASA NTRS1973

Computer design of antenna reflectors.

Performance of paraboloidal antenna reflectors is adversely influenced by surface distortions from a perfect paraboloid, which cause pathlength variations of the RF energy beam. The structural design objective for the surface backup structure is to minimize the rms pathlength deviations for gravity loading. Two design approaches are illustrated and applied to sample antenna structure designs. These are a sectional search method and a virtual work/Lagrange multiplier method. Both are shown to provide useful performance improvements. The second, however, appears to be more suited for application to design of large antenna structures.

Levy, R.↗

NASA NTRS1988

Control of optical systems

Some of the current and planned activities at the Air Force Systems Command in structures and controls for optical-type systems are summarized. Many of the activities are contracted to industry; one task is an in-house program which includes a hardware test program. The objective of the in-house program, referred to as the Aluminum Beam Expander Structure (ABES), is to address issues involved in on-orbit system identification. The structure, which appears similar to the LDR backup structure, is about 35 feet tall. The activity to date has been limited to acquisition of about 250 hours of test data. About 30 hours of data per excitation force is gathered in order to obtain sufficient data for a good statistical estimate of the structural parameters. The development of an Integrated Structural Modeling (ISM) computer program is being done by Boeing Aerospace Company. The objective of the contracted effort is to develop a combined optics, structures, thermal, controls, and multibody dynamics simulation code.

Founds, D.↗

NASA NTRS1986

System concept for a moderate cost Large Deployable Reflector (LDR)

A study was carried out at JPL during the first quarter of 1985 to develop a system concept for NASA's LDR. Major features of the concept are a four-mirror, two-stage optical system; a lightweight structural composite segmented primary reflector; and a deployable truss backup structure with integral thermal shield. The two-stage optics uses active figure control at the quaternary reflector located at the primary reflector exit pupil, allowing the large primary to be passive. The lightweight composite reflector panels limit the short-wavelength operation to approximately 30 microns but reduce the total primary reflector weight by a factor of 3 to 4 over competing technologies. On-orbit thermal analysis indicates a primary reflector equilibrium temperature of less than 200 K with a maximum gradient of about 5 C across the 20-m aperture. Weight and volume estimates are consistent with a single Shuttle launch, and are based on Space Station assembly and checkout.

Swanson, P. N.↗

NASA NTRS1988

Joints in deployable space truss structures

Since the response of deployable structural concepts being considered for the Large Deployable Reflector (LDR) backup structure will be dominated by the response of joints, the joint characteristics are significant. An overview is given of the research activities at LaRC on the static behavior of joints for deployable space truss structures. Since a pin-clevis-type joint will be utilized in deployable structures, an experimental research program to characterize the joint parameters which affect stiffness was conducted. An experimental research program was conducted on a second type of joint, referred to as a near-center latch joint. It was used in the center of members on the deployable truss structure for the Control of Flexible Structures (COFS) flight experiment. The test results of the near-center latch joint and the member with the joints indicated that the stiffness of the near-center joint is linear and stiffer than the stiffness of the total member, and that non-linearities in the stiffness characteristics of the total member were due to bending introduced at the ends of the member. The resulting data indicates that stiff linear folding joints can be designed and that bending load paths should be avoided whenever possible. In summary, for deployable structures, special attention to the joint and the structure design is required to minimize the undesirable structural non-linearities.

Rhodes, M.↗

NASA NTRS1988

Initial test results for the mini-mast

The objectives of the 20-meter Mini-Mast were: (1) to learn how to efficiently test this type of large truss structure, (2) to relate component testing to the overall behavior of the structure, and (3) to update the associated analytical model based upon the experimental data. The Mini-Mast represents structural characteristics similar to the COFS beam which is planned to be flown on Shuttle to perform on-orbit structures and controls experiments. The information is of interest to LDR because it represents analysis and test information on a truss-type structure which may be similar to the Large Deployable Reflector (LDR) backup structure. The structure has a total of 111 titanium joints; the joint in the center of the truss element is a near-center latch joint. The results of this research indicate that linear deployable-type structures can be built, but difficulties do exist in extracting modes with identical frequencies; gravitational loading does affect the ground test results; and prediction of truss-type-structure dynamic characteristics is not trivial.

Horta, L.↗

NASA NTRS1989

Reducing distortion and internal forces in truss structures by member exchanges

Manufacturing errors in the length of members or joint diameters of large truss reflector backup structures may result in unacceptable large distortion errors or member forces. However, it may be possible to accurately measure these length or diameter errors. The present work suggests that a member and joint placement strategy may be used to reduce distortion errors and internal member forces. A member and joint exchange algorithm is used to demonstrate the potential of this approach on several 102-member and 660-member truss reflector structures. It is shown that it is possible to simultaneously reduce the rms of the surface error and the rms of member forces by two orders of magnitude by member and joint exchanges.

Greene, William H.↗

NASA NTRS1990

Reducing distortion and internal forces in truss structures by member exchanges

Greene, William H.↗

NASA NTRS1989

Minimizing distortion and internal forces in truss structures by simulated annealing

Inaccuracies in the length of members and the diameters of joints of large truss reflector backup structures may produce unacceptable levels of surface distortion and member forces. However, if the member lengths and joint diameters can be measured accurately it is possible to configure the members and joints so that root-mean-square (rms) surface error and/or rms member forces is minimized. Following Greene and Haftka (1989) it is assumed that the force vector f is linearly proportional to the member length errors e(sub M) of dimension NMEMB (the number of members) and joint errors e(sub J) of dimension NJOINT (the number of joints), and that the best-fit displacement vector d is a linear function of f. Let NNODES denote the number of positions on the surface of the truss where error influences are measured. The solution of the problem is discussed. To classify, this problem was compared to a similar combinatorial optimization problem. In particular, when only the member length errors are considered, minimizing d(sup 2)(sub rms) is equivalent to the quadratic assignment problem. The quadratic assignment problem is a well known NP-complete problem in operations research literature. Hence minimizing d(sup 2)(sub rms) is is also an NP-complete problem. The focus of the research is the development of a simulated annealing algorithm to reduce d(sup 2)(sub rms). The plausibility of this technique is its recent success on a variety of NP-complete combinatorial optimization problems including the quadratic assignment problem. A physical analogy for simulated annealing is the way liquids freeze and crystallize. All computational experiments were done on a MicroVAX. The two interchange heuristic is very fast but produces widely varying results. The two and three interchange heuristic provides less variability in the final objective function values but runs much more slowly. Simulated annealing produced the best objective function values for every starting configuration and was faster than the two and three interchange heuristic.

Kincaid, Rex K.↗

NASA NTRS1992

Active figure maintenance control using an optical truss laser metrology system for a space-based far-IR segmented telescope

A two-stage active control approach was developed addressing the figure control problem for a spaceborne FIR telescope, the Precision Segmented Reflectors Focus Moderate Mission Telescope (FMMT). The first active control stage aligns the optical segments based on images; attention is here given to the second stage, active figure maintenance control system, which maintains the alignment of the optical elements between initializations to hold the mirror figure steady while obtaining data and fixes translational and rotational changes of the optical segments induced by long-term thermal drifts of the support structure. Errors are expected to be 10-100 microns at the nodes of the primary backup structure over the course of an orbit. An rms performance of 0.8 microns of wavefront error can be expected during the maintenance function based on specified nominal sensor noises, actuator accuracies, and system environments. A performance of less than 0.3 microns rms can be expected, based on advanced components.

Lau, Kenneth↗

NASA NTRS2008

Wear and Tear - Mechanical

The focus of this chapter is on the long term wear and tear, or aging, of the mechanical subsystem of a spacecraft. The mechanical subsystem is herein considered to be the primary support structure (as in a skeleton or exoskeleton) upon which all other spacecraft systems rest, and the associated mechanisms. Mechanisms are devices which have some component that moves at least once, in response to some type of passive or active control system. For the structure, aging may proceed as a gradual degradation of mechanical properties and/or function, possibly leading to complete structural failure over an extended period of time. However, over the 50 years of the Space Age such failures appear to be unusual. In contrast, failures for mechanisms are much more frequent and may have a very serious effect on mission performance. Just as on Earth, all moving devices are subject to normal (and possibly accelerated) degradation from mechanical wear due to loss or breakdown of lubricant, misalignment, temperature cycling effects, improper design/selection of materials, fatigue, and a variety of other effects. In space, such environmental factors as severe temperature swings (possibly 100's of degrees C while going in and out of direct solar exposure), hard vacuum, micrometeoroids, wear from operation in a dusty or contaminated environment, and materials degradation from radiation can be much worse. In addition, there are some ground handling issues such as humidity, long term storage, and ground transport which may be of concern. This chapter addresses the elements of the mechanical subsystem subject to wear, and identifies possible causes. The potential impact of such degradation is addressed, albeit with the recognition that the impact of such wear often depends on when it occurs and on what specific components. Most structural elements of the mechanical system typically are conservatively designed (often to a safety factor of greater than approximately 1.25 on yield for unmanned spacecraft) but do not have backup structure due to the added mass this would impose, and also due to the fact that structural elements can be accurately modeled mathematically and in test. Critical mechanisms or devices may have backups, or alternate work-arounds, since characterization of these systems in a 1g environment is less accurate than structure, and repair in-space is often impossible.

Swanson, Theodore↗

NASA NTRS1988

LDR structural technology activities at JPL

The status of the Large Deployable Reflector (LDR) technology requirements and the availability of that technology in the next few years are summarized. The research efforts at JPL related to these technology needs are also discussed. LDR requires that a large and relatively stiff truss-type backup structure have a surface accurate to 100 microns in space (initial position with thermal distortions) and the dynamic characteristics predictable and/or measurable by on-orbit system identification for micron level motion. This motion may result from the excitation of the lower modes or from wave-type motions. It is also assumed that the LDR structure can be ground tested to validate its ability to meet mission requirements. No program manager will commit a structural design based solely on analysis, unless the analysis is backed by a validation test program.

Wada, Ben↗