Deployable Boom Research Articles

Design, fabrication and experimental verification of a drag sail based on thermal-driven controllable bi-stable shape memory polymer composite booms

Deployable drag sails are used for passively deorbiting defunct satellites and other spacecraft. Designing the deployable boom is the main challenge in this technology. We present a bi-stable shape memory polymer composite (Bi-SMPC) boom with high stiffness, a high unfolding/folding ratio, and consistent roll-out deployment. It was designed and fabricated by a strategy of controlling the gradual release of elastic energy stored in a bi-stable composite structure through thermal-driven SMP matrix. Two heating layer strategies were investigated experimentally to determine the optimal driving layer and driving parameters. Based on these parameters, verification tests of a four-stage deployment Bi-SMPC boom were conducted. Meanwhile, a proof-of-concept prototype of a four-stage deployment drag sail based on the Bi-SMPC booms was designed and fabricated. Tests were conducted to verify the effectiveness of the drag sail deployed by the booms. It was found that SMPs can effectively control the deployment of bistable composite structures. The nickel-chromium alloy heating layer offers a more uniform driving temperature field compared to carbon fiber. The drag sail can be deployed successfully under the driving of four Bi-SMPC booms.

Free Vibration of a Panel Supported by a Shear Compliant Two-Flexure Hinge

Elastically deformable hinges or deployable booms commonly follow architectures with face-skin layers only, cutting out the core to facilitate folding. This significantly reduces the shear stiffness of the hinge, which might reduce the first resonance frequency of the structure. We rationalize the free vibration of the system and the interplay between shearing and bending deformation by deriving an analytical formulation using Timoshenko’s beam theory. The framework is derived for a general beam and applied to a case of two flexures of arbitrary geometry with no core. Investigating the specific geometry of flat flexures reveals the existence of two nondimensional length ratios that capture the interplay between inertia, bending stiffness, and shear stiffness of the hinge. Our model explains the dependence of the frequency on the parameters of the system, as well as the dimensions that determine the transition between bending- and shear-dominated vibration modes. Comparison with finite element simulations shows that our analytic framework is able to predict the first natural frequency with less than 1% error. Additionally, an experimental validation was carried out using steel flexures and acrylic panels, showing good agreement with the predictions.

Structural Properties of Deployable Booms for Communications Satellites

Structural Properties of Deployable Booms for Communications Satellites

Enabling Boomless CubeSat Magnetic Field Measurements With the Quad‐Mag Magnetometer and an Improved Underdetermined Blind Source Separation Algorithm

AbstractIn situ magnetic field measurements are often difficult to obtain due to the presence of stray magnetic fields generated by spacecraft electrical subsystems. The conventional solution is to implement strict magnetic cleanliness requirements and place magnetometers on a deployable boom. However, this method is not always feasible on low‐cost platforms due to factors such as increased design complexity, increased cost, and volume limitations. To overcome these problems, we propose using the Quad‐Mag CubeSat magnetometer with an improved Underdetermined Blind Source Separation (UBSS) noise removal algorithm. The Quad‐Mag consists of four magnetometer sensors in a single CubeSat form‐factor card that allows distributed measurements of stray magnetic fields. The UBSS algorithm can remove stray magnetic fields without prior knowledge of the magnitude, orientation, or number of noise sources. UBSS is a two‐stage algorithm that identifies signals through cluster analysis and separates them through compressive sensing. We use UBSS with single‐source point detection to improve the identification of noise signals and iteratively‐weighted compressed sensing to separate noise signals from the ambient magnetic field. Using a mock CubeSat, we demonstrate in the lab that UBSS reduces four noise signals producing more than 100 nT of noise at each magnetometer to below the expected instrument resolution (5 nT at 65 Hz). Additionally, we show that the integrated Quad‐Mag and improved UBSS system works well for 1U, 2U, 3U, and 6U CubeSats in simulation. Our results show that the Quad‐Mag and UBSS noise cancellation package enables high‐fidelity magnetic field measurements from a CubeSat without a boom.

Roll-Out Deployment Process Analysis of a Fiber Reinforced Polymer (FRP) Composite Tape-Spring Boom.

Deployable extendable booms are widely used in aerospace technology due to many advantages they have, such as high folded-ratio, lightweight and self-deployable properties. A bistable FRP composite boom can not only extend its tip outwards with a corresponding rotation speed on the hub, but can also drive the hub rolling outwards with a fixed boom tip, which is commonly called roll-out deployment. In a bistable boom's roll-out deployment process, the second stability can keep the coiled section from chaos without introducing a controlling mechanism. Because of this, the boom's roll-out deployment velocity is not under control, and a high moving speed at the end will give the structure a big impact. Therefore, predicting the velocity in this whole deployment process is necessary to be researched. This paper aims to analyze the roll-out deployment process of a bistable FRP composite tape-spring boom. First, based on the Classical Laminate Theory, a dynamic analytical model of a bistable boom is established through the energy method. Afterwards, an experiment is introduced to produce some practical verification for comparison with the analytical results. According to the comparison with the experiment, the analytical model is verified for predicting the deployment velocity when the boom is relatively short, which can cover most booms using CubeSats. Finally, a parametric study reveals the relationship between the boom properties and the deployment behaviors. The research of this paper will give some guidance to the design of a composite roll-out deployable boom.

Configuration Design and Dynamic Characteristics Analysis for Space Membrane Mechanism Based on Deployable Booms

To meet the requirements of deployable structures in aerospace engineering with light weight and high stiffness, this paper proposes the triangular space membrane deployable mechanism based on deployable booms, then conducts dynamic analysis and multiobjective optimization. The configuration design and mass calculation for the membrane mechanism are carried out, including its unfolding support mechanism and tensioned membrane scheme. With a view to performing the dynamic characteristics analysis and parametric studies, the finite element simulation model of the membrane mechanism, including boom, cable and membrane, is built and validated against test results obtained by Polytec. On the basis of the simulation results, a surrogate model of fundamental frequency is established by adopting the response surface method and applied to multiobjective optimization combined with the mass formula. Then, the optimal dynamic and lightweight design parameters are solved via the genetic algorithm. The results provide an indication to aid with the design and analysis of space membrane deployable mechanisms according to the required properties and space mission requirements.

Research on forming and mechanical properties for one dimensional linear deployable boom Stacer of spacecraft

Research on forming and mechanical properties for one dimensional linear deployable boom Stacer of spacecraft

Numerical simulation of the sensor output on Macau Science Satellite-1

Macau Science Satellite-1 (MSS-1) will be launched at the early of 2023 into a near-circular orbit. The mission is designed to measure the Earth’s geomagnetic field with unpreceded accuracy through a new perspective. The most important component installed on the satellite, to ensure high accuracy, is the deployable boom (Optical Bench). A Vector Field Magnetometer (VFM), an Advanced Stellar Compass (ASC), and a Couple Dark State Magnetometers (CDSM) are deployed on the deployable boom. In order to maximize the mission’s scientific output, a numerical simulator on MSS-1’s deployable boom was required to evaluate the adaptability of all devices on the deployable boom and assist the satellite’s data pre-processing. This paper first briefly describes the synthesis of the Earth’s total magnetic field and then describes the method simulating the output of scalar and vector magnetometers. Finally, the calibration method is applied to the synthetic magnetometer data to analyze the possible noise/error of the relevant instruments. Our results show that the simulator can imitate the disturbance of different noise sources or errors in the measuring system, and is especially useful for the satellite's data processing group.

Design and Verification of Continuous Moulding Process of Ultra-long Thin-walled Deployable Boom

Design and Verification of Continuous Moulding Process of Ultra-long Thin-walled Deployable Boom

Numerical simulation of deployable ultra-thin composite shell structures for space applications and comparison with experiments

In the present article, the geometrical nonlinear behavior of deployable booms undergoing large displacements and rotations is investigated. The triangular rollable and collapsible boom made of fiber-reinforced composite materials is considered along with a metallic tape spring. The mathematical model makes use of higher-order 1D structural theories based on the Carrera unified formulation, which allows the description of moderate nonlinearities to deep post-buckling mechanics of ultra-thin shells in a hierarchical and scalable manner. Particular attention is focused on the study of equilibrium paths of the booms subjected to coiling bending. Dedicated experimental tests reveal the validity of the proposed finite element approach, whereas the investigation of different lamination sequences offer a valuable perspective for possible future designs.

Novel Four-Cell Lenticular Honeycomb Deployable Boom with Enhanced Stiffness.

Composite thin-walled booms can easily be folded and self-deployed by releasing stored strain energy. Thus, such booms can be used to deploy antennas, solar sails, and optical telescopes. In the present work, a new four-cell lenticular honeycomb deployable (FLHD) boom is proposed, and the relevant parameters are optimized. Coiling dynamics analysis of the FLHD boom under a pure bending load is performed using nonlinear explicit dynamics analysis, and the coiling simulation is divided into three consecutive steps, namely, the flattening step, the holding step, and the hub coiling step. An optimal design method for the coiling of the FLHD boom is developed based on a back propagation neural network (BPNN). A full factorial design of the experimental method is applied to create 36 sample points, and surrogate models of the coiling peak moment (Mpeak) and maximum principal stress (Smax) are established using the BPNN. Fatigue cracks caused by stress concentration are avoided by setting Smax to a specific constraint and the wrapping Mpeak and mass of the FLHD boom as objectives. Non-dominated sorting genetic algorithm-II is used for optimization via ISIGHT software.

Deployable boom for Mars Orbiter Magnetometer onboard “Tianwen-1”

A more than 3-m long deployable boom is an essential component of the Mars Orbiter Magnetometer (MOMAG) onboard the orbiter of “Tianwen-1”. The boom was developed to place fluxgate magnetometer (FGM) sensors away from the satellite to reduce the influence of the satellite magnetic field. It was designed as an articulated spring-driven deployable mechanism for single-shot deployment. Functionality, reliability and system constraints are fully considered in the boom design. Mechanical analyses and proof tests show that the boom has sufficient safety margin to withstand environmental conditions, even in the worst cases. After a long voyage from Earth to Mars, the boom was deployed successfully on May 25, 2021. A full deployment was performed in approximately 4.6 s, sending the two sensors to distances of 3.19 m and 2.29 m respectively, away from the orbiter. After deployment, the field from the orbiter decreased from 1250 nT to less than 6 nT at the sensor mounted at the tip of the boom. The MOMAG boom provides valuable engineering experience for the development of deployable structures stowed for long periods in cold temperatures in space missions.

Deployable boom for Mars Orbiter Magnetometer onboard Tianwen-1

A more than 3 m-long deployable boom is an essential component of the Mars Orbiter Magnetometer (MOMAG) onboard the orbiter of Tianwen-1. The boom was developed to place fluxgate magnetometer (FGM) sensors away from the satellite to reduce the influence of the satellite magnetic field. It was designed as an articulated spring-driven deployable mechanism for single-shot deployment. Functionality, reliability and system constraints are fully considered in the boom design. Mechanical analyses and proof tests show that the boom has sufficient safety margin to withstand environmental conditions, even in the worst cases. After a long voyage from Earth to Mars, the boom was deployed successfully on May 25, 2021. A full deployment was performed in about 4.6 s, sending the two sensors to distances of 3.19 m and 2.29 m respectively, away from the orbiter. After deployment, the field from the orbiter decreased from 1250 nT to less than 6 nT at the sensor mounted at the tip of the boom. The MOMAG boom provides valuable engineering experience for the development of deployable structures stowed for long periods in cold temperatures in space missions.

Passive damped deployment of full composite structures

A new material, currently used in non-spatial applications, with interesting properties has been identified: a flexible epoxy resin with lower stiffness and higher damping than the space used resins and that is miscible with these ones. Such a mixed material could be used in CFRP components which properties (stiffness and damping) could be customised. One possible application has been selected for this study: the deployment of full CFRP structures composed of thin-walled composite deployable booms with tape-spring hinges on them. These kind of passive springs have been shown to be very powerful, but they have also shown a hard dynamic behaviour that can produce damages to the deployed items or their hosting structure. The partial use of flexible epoxy resins in the CFRP hinges can introduce an efficient damping in the deployment and relief of this dynamic effect. The objective of this activity is to verify the feasibility of the use of a mixture of rigid and flexible epoxy resins for obtaining better dynamic performances of CFRP tape springs. The results of this study are very promising. They show that it is possible to customise the properties of some components by finding the adequate mixture of resins. However, additional studies are necessary to assess good performances in space environment. The validation of this material can open the door to new space applications where the proper combination of stiffness and damping is crucial.

Simplified Analytical Model for Predicting Neutral Cross-Section Position of Lenticular Deployable Composite Boom in Tensile Deformation.

Foldable and deployable flexible composite thin-walled structures have the characteristics of light weight, excellent mechanical properties and large deformation ability, which means they have good application prospects in the aerospace field. In this paper, a simplified theoretical model for predicting the position of the neutral section of a lenticular deployable composite boom (DCB) in tensile deformation is proposed. The three-dimensional lenticular DCB is simplified as a two-dimensional spring system and a rigid rod, distributed in parallel along the length direction. The position of the neutral cross-section can be determined by solving the balance equations and geometric relations. In order to verify the validity of the theoretical model, a finite element model of the tensile deformation of a lenticular DCB was established. The theoretical prediction results were compared with the finite element calculation results, and the two results were in good agreement.

Deep learning-based Structural Health Monitoring for damage detection on a large space antenna

Due to the stringent requirements imposed by state-of-the-art technologies, most of modern spacecrafts are now equipped with very large substructures such as antennas, deployable booms and solar arrays. However, while the size of these elements increases, their mass is limited by the rocket maximum take-off weight and, therefore, they result to be lightweight and very flexible. A natural concern derived from this trend is that these structures are now more susceptible to structural damages during launch phase or operational life (impacts, transient thermal states and fatigue). Since the degradation of some structural elements would naturally result in a modification of the system dynamical behaviour, damage detection processes are usually performed by comparing the dynamical responses or the structural model matrices (i.e. stiffness, mass and damping) of the undamaged model with those of the damaged structure. However, for large structures, the presence of local damage does not generally induce substantial change in the global dynamic which makes the local failures difficult to detect. A methodology for structural damage detection based on data-driven techniques with Deep Neural Network (DNN) is hereby proposed for the study of a large in-orbit flexible system. The deep architecture evaluated in this work is composed by stacking several neural network layers with different functions. In order to generate data for training and testing the machine learning model, different damage scenarios are generated via Finite Element commercial code and, based on the extracted modal parameters, the fully coupled 3D equations for the flexible spacecraft are integrated to test typical profiles of attitude manoeuvres. The DNN model is trained using the sensor-measured time series responses, where each of the former has been associated with the label of the corresponding damage scenario.

Development of Forming Method of Deployable Boom from Thermoplastic Polymer Composite

This paper studies deployable elements which are used in satellites and different terrestrial antenna devices. Many deployable elements are made from steel or thermoset polymer composite materials and have the following disadvantages like length limitation of deployable elements, labour intensity of manufacturing process of deployable elements etc. For this purpose a deployable tube boom element was chosen and a forming method for manufacturing deployable tube element from thermoplastic polymer composite material was developed.

ADEO: the European commercial passive de-orbit subsystem family enabling space debris mitigation

The ADEO subsystem is a scalable drag augmentation device that uses the residual Earth atmosphere present in Low Earth Orbit (LEO) to passively de-orbit of satellites between 1 and 2000 kg. For the de-orbit maneuvre, a large surface is deployed which multiplies the drag effective surface of the satellite significantly. Thereby the drag force is increased as well causing accelerated decay in orbit altitude. Advantageous about a drag augmentation device is that it does not require any active steering and can be designed for passive attitude stabilization thereby making it applicable for non-operational, tumbling spacecrafts as well. The ADEO subsystem consists of four deployable booms that span four sail segments in a planar shaped configuration. While the sails are made of an aluminum-coated polyimide foil, its coating thickness was chosen such that it provides sufficient protection from the LEO space environment. The current activity commenced in August 2018 is going to provide a fully qualified Protoflight Model (PFM) for a follow-up “In Orbit Demonstration” (IOD) in 2021/2022 (ADEO is selected as payload on the European Commission IOD/IOV satellite programme). In May 2020, the team passed the Manufacturing Readiness Review (MRR). An extensive Breadboarding- and Engineering Model campaign including life tests had already been carried out in 2019. The first ADEO-L PFM consists of a 5 m x 5 m dragsail deployed under control of own onboard electronics. Optionally, ADEO-L systems can be equipped with a so-called “watchdog routine” inside the electronics which is able to recognize the point in time when the satellite has come to the end of its life circle. With the help of an on-board battery the sail will be deployed automatically after a certain time in orbit. Operating like this, ADEO-L can be truly called “100% passive”, a “CleanGreen Space Mission”. First commercial candidate missions to be targeted after the successful EC-IOD mission were already identified by Airbus DS (DE) and QinetiQ (BE).

Thermal stresses in composite cylindrical lattices

Deployable spacecraft technology should be both lightweight and compact for storage while also being rigid and expansive once deployed. A new type of structure that can meet both of these requirements is the morphing cylindrical lattice. This multi-stable structure can morph from a compact stowed state, to a long and slender deployed beam. It comprises narrow strips of carbon fibre composite material, making it particularly suitable for deployable booms, solar arrays and antennae. While existing modelling techniques focus on predicting the stability of lattices using symmetrical laminates, current work extends upon state-of-the-art by including the effects of thermal strains and curvatures that arise in non-symmetrical laminates when cured at elevated temperatures. As non-symmetrical laminates cool during post-cure, thermal stresses increasingly develop due to the variation of in-plane thermal expansion coefficient through the thickness. The model developed in this work, includes thermal stress effects, allowing for the design of thermally actuating lattices. This model is verified through comparison with finite element analysis and experimental data, both of which show excellent agreement.

Folding and Stiffness Analysis for Thin-walled Deployable Boom

Folding and Stiffness Analysis for Thin-walled Deployable Boom