Considering Manufacturability in the Design of Deployable Origami-Adapted Mechanisms

Primary barriers to greater implementation of deployable origami-adapted mechanisms are their manufacturability and robustness. This paper discusses manufacturability in the design of such mechanisms through presenting and examining three examples. Manufacturability lessons gathered from these examples include the importance of joint-panel interfaces and how techniques and approaches for origami-adapted design can be customized to meet the needs of a specific product. As the manufacturability of deployable origami-adapted products is addressed and improved, their robustness will also improve, thereby enabling greater use of origami-adapted design

Deployment Methods for an Origami-Inspired Rigid-Foldable Array

The purpose of this work is to evaluate several deployment methods for an origami-inspired solar array at two size scales: 25-meter array and CubeSat array. The array enables rigid panel deployment and introduces new concepts for actuating CubeSat deployables. The design for the array was inspired by the origami flasher model (Lang, 1997; Shafer, 2001). Figure 1 shows the array prototyped from Garolite and Kapton film at the CubeSat scale. Prior work demonstrated that rigid panels like solar cells could successfully be folded into the final stowed configuration without requiring the panels to flex (Zirbel, Lang, Thomson, & al., 2013). The design of the array is novel and enables efficient use of space. The array can be wrapped around the central bus of the spacecraft in the case of the large array, or can accommodate storage of a small instrument payload in the case of the CubeSat array. The radial symmetry of this array around the spacecraft is ideally suited for spacecraft that need to spin. This work focuses on several actuation methods for a one-time deployment of the array. The array is launched in its stowed configuration and it will be deployed when it is in space. Concepts for both passive and active actuation were considered

A New Self-Adjusting CVT Configuration Using Compliant Mechanisms

ABSTRACT This paper introduces a new configuration of a Continuously Variable Transmission (CVT) that is self-adjusting and designed as a compliant mechanism. This new configuration is called the Pivot-Arm CVT. The criteria for classification as a Pivot-Arm CVT is discussed. An analytical model describing the performance of the Pivot-Arm CVT is developed. Special design considerations which may be useful in implementing Pivot-Arm CVTs are introduced and explained. The Pivot-Arm CVT model is validated through controlled testing of two Pivot-Arm CVT prototypes

The Compliant A-Arm Suspension

ABSTRACT The use of compliant mechanisms in a suspension system has been demonstrated with leaf spring mechanisms. In this research a novel compliant configuration called the Compliant A-Arm (C-A-Arm) suspension is selected for in-depth study. Closedform equations are derived for linear small-deflection stiffness equations. Large deflections are analyzed using finite element analysis. A pseudo-rigid-body model is developed to approximate mechanism deflections and stiffness for large deflections. The results suggest that the C-A-Arm configuration may be a viable suspension alternative for future commercial application. In addition, this configuration offers a number of performance variables that could be the basis for an active control system. This paper represents a necessary first step in modeling this new configuration

A Preliminary Review and Discussion of Metrics for Origami-Based Deployable Arrays

When designing deployable structures, there are many things to consider that help the deployment method integrate with the system. Preliminary metrics are proposed to help rate the deployment systems to determine the best methods for each application. The top four metrics that apply to most space applications are mass, usable area, volume, and energy. Additional considerations that are less quantifiable are included for the value they contribute to the system. Trade-offs may be necessary for different applications

Principles for Designing Origami-Inspired Composite Space Structures with High-Strain Compliant Laminate Joints

In space missions, many methods and techniques are used to enable large deployable structures—such as solar arrays, antennas, and radiators—for power, communication, and heat regulation. With origami as inspiration, a new class of self-deployable, self-stiffening, and retractable (SDSR) array has been developed and is reviewed. SDSR arrays are a scalable deployable architecture based on origami flasher patterns. They do not require the aid of external support and actuation structures common in space applications, instead replacing them with strained compliant joints and reeling cables. Aluminum construction has previously been successfully modeled and demonstrated, however, SDSR technology can be greatly improved with more advanced, lighter weight materials. This work presents the redesign of the SDSR array for construction from CFRP composite laminates, including principles developed for the design of high-strain composite flexural joints and their integration into composite panels that can be applied broadly in other sheetlike folding composite structures. The flexural joint used is an array of lamina emergent torsional (LET) joints, and is an innovative solution to attain large deflections needed for hinge-like motion in large foldable arrays. The research that has been done in LET joints assumes an isotropic material, whereas LET joints in anisotropic materials such as CFRPs have yet to be addressed in the literature. Panel flatness is an area of interest so deflections are analysed assuming a rectangular panel and basic panel deflection techniques. The culmination of the design and modeling is the demonstration of two prototype composite arrays, the second array overcoming weaknesses in the initial design