Design and Prototype Verification of a 3-meter Aperture Wrap-rib Reflector
ObjectiveCFRP lenticular tube wrap-rib reflector is light in weight, simple in structure, has a high stowage ratio, high deployment reliability, and offers good application prospects for both small-aperture and several-meter large-aperture deployable antennas. Currently, the application of this type...
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Editorial Department of Journal of Sichuan University (Engineering Science Edition)
2025-01-01
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| Series: | 工程科学与技术 |
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| Online Access: | http://jsuese.scu.edu.cn/thesisDetails#10.12454/j.jsuese.202400644 |
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| author | ZHANG Han YAN Zhongxi XIANG Ping WU Minger |
| author_facet | ZHANG Han YAN Zhongxi XIANG Ping WU Minger |
| author_sort | ZHANG Han |
| collection | DOAJ |
| description | ObjectiveCFRP lenticular tube wrap-rib reflector is light in weight, simple in structure, has a high stowage ratio, high deployment reliability, and offers good application prospects for both small-aperture and several-meter large-aperture deployable antennas. Currently, the application of this type of deployable reflector mainly faces two challenges: ensuring the reliability of stowage and deployment strategies for large-deformation wrapping, and achieving and maintaining surface accuracy of the flexible wrap-rib reflector. This paper proposes a CFRP lenticular tube wrap-rib reflector scheme, and its stowage and deployment performance, as well as surface accuracy, were analyzed and tested.MethodsFirstly, a 3 m aperture wrap-rib reflector scheme for X-band was proposed, which includes the central hub, wrap-ribs, metal mesh, side cables, and the locking and unlocking device. The wrap-ribs were made of lightweight, high-strength, and high-stiffness CFRP lenticular tubes, and the [45°/-45°/-45°/45°] lay-up and section design were achieved using prepregs with a single layer thickness of 0.05 mm. To ensure the installation accuracy and deployment rigidity of the wrap-ribs, they were fixedly connected to the central hub. In order to solve the problem of high stress in the root area of the wrapped wrap-ribs, a method of setting a wrapping guide on the root area of the wrap-ribs was proposed. A finite element model was established based on the material parameters obtained from the tensile test, and the stress during the wrapping process of a single CFRP lenticular tube with a wrapping guide was analyzed using the explicit dynamic method. Secondly, according to the requirements of the X-band, the surface accuracy of the 3-meter aperture reflector was estimated using an approximate theoretical formula. The focal length-to-aperture ratio of the reflector and the number of wrap-ribs were selected. Due to the low stiffness of the wrap-rib reflector, the wrap-ribs deform to a certain degree during the forming process of the reflector, and the back-pillow effect appears in each sector mesh. Both of these factors affect the surface accuracy of the reflector. To solve this problem, the shape of the flexible wrap-rib reflector was determined through form-finding analysis. The shape of the lenticular tube wrap-rib was optimized by combining the form-finding analysis of the flexible reflector with the genetic algorithm. Finally, a reflector prototype was designed and assembled, and the deploying test, fundamental frequency test and surface accuracy measurement were carried out.Results and Discussions Adding a wrapping guide to the root area of CFRP lenticular tube wrap-rib can prevent excessive wrapping stress in this area and improve the wrapping performance of the wrap-rib reflector. The focal length-to-aperture ratio of the reflector is 0.55, the number of wrap-ribs is 36, and the RMSE value of the estimated surface accuracy calculated by the theoretical formula is 0.89 mm, which meets the application requirements for X-band. When the upper edge curve of the wrap-rib of the reflector lies on the design paraboloid, the surface accuracy of the reflector after form-finding analysis is 1.51 mm, which is significantly higher than the 0.89 mm calculated by the theoretical formula. This discrepancy arises because the elastic deformation of the wrap-ribs and the back-pillow effect of the metal mesh cause the metal mesh to deviate from its initial position after the form-finding analysis of the flexible wrap-rib reflector. Taking the root of the wrap-rib as the origin, the curve equation of the wrap-rib after optimization is <inline-formula><alternatives><math xmlns:mml="http://www.w3.org/1998/Math/MathML" id="M1"><mi>z</mi><mo>=</mo><mn mathvariant="normal">0.000148</mn><msup><mrow><mi>x</mi></mrow><mrow><mn mathvariant="normal">2</mn></mrow></msup><mo>+</mo><mn mathvariant="normal">0.0359</mn><mi>x</mi></math><graphic specific-use="big" xmlns:xlink="http://www.w3.org/1999/xlink" xlink:href="alternativeImage/30D0F351-5FEC-4cd7-9CCF-CA71966FC3ED-M001.jpg"><?fx-imagestate width="28.70199966" height="2.28600001"?></graphic><graphic specific-use="small" xmlns:xlink="http://www.w3.org/1999/xlink" xlink:href="alternativeImage/30D0F351-5FEC-4cd7-9CCF-CA71966FC3ED-M001c.jpg"><?fx-imagestate width="28.70199966" height="2.28600001"?></graphic></alternatives></inline-formula> (0 mm ≤ x ≤ 1410 mm), and the surface accuracy of the reflector is 0.78 mm, which is obviously better than the 1.51 mm before the shape optimization of the wrap-rib. By optimizing the shape of the wrap-rib, the surface accuracy of the reflector was effectively improved. The mass of the wrap-rib reflector prototype is about 6 kg, and the stowage size is 0.7m × 0.7m × 0.15m. It took about 6 seconds from the time the Dyneema rope was fused until the reflector was fully deployed. The deployment test verified both the stowage mode of the CFRP lenticular tube wrap-rib reflector and the deployment mode driven by the elastic energy of the wrap-ribs. At the same time, the feasibility of the proposed stowage tool and the locking and unlocking device was also verified. The measured fundamental frequency of the deployed reflector prototype is about 1.69 Hz, indicating good overall rigidity. In the surface accuracy measurement, the best self-fitting paraboloid of condition 1 was taken as the reference. The difference in surface accuracy between after installation and after one stowage and deployment is minimal, and it is close to the theoretical design value. After four deployments and three days of placement, the surface error increases slightly but remains below the design target value of 1 mm. The reflector prototype's surface has basically achieved the design goal for surface accuracy. The surface accuracy measurement test results show that the reflector prototype exhibits stable surface accuracy, although the surface accuracy of the reflector decreases slightly after long-term stowage and multiple stowage and deployment cycles.ConclusionsThe results show that the CFRP lenticular tube wrap-rib reflector scheme has the advantages of a simple structure, light weight, high storage ratio, and good overall rigidity. The wrapping guides and the locking and unlocking device contribute to improving the reliability of stowage and deployment. By optimizing the shape of the wrap-rib, the flexible wrap-rib reflector can achieve good and stable surface accuracy. The CFRP lenticular tube has the characteristics of light weight, easy wrapping, and high rigidity after deployment, making it an important option for selecting wrap-ribs in wrap-rib reflectors. Further research should be carried out in the future on the reflector performance under multiple stowage and deployment cycles, long-term storage, and on-orbit environments, as well as the maintenance of surface accuracy. |
| format | Article |
| id | doaj-art-ca6ec141af6249a2ae7622001edf64bd |
| institution | OA Journals |
| issn | 2096-3246 |
| language | English |
| publishDate | 2025-01-01 |
| publisher | Editorial Department of Journal of Sichuan University (Engineering Science Edition) |
| record_format | Article |
| series | 工程科学与技术 |
| spelling | doaj-art-ca6ec141af6249a2ae7622001edf64bd2025-08-20T02:10:20ZengEditorial Department of Journal of Sichuan University (Engineering Science Edition)工程科学与技术2096-32462025-01-0111187950239Design and Prototype Verification of a 3-meter Aperture Wrap-rib ReflectorZHANG HanYAN ZhongxiXIANG PingWU MingerObjectiveCFRP lenticular tube wrap-rib reflector is light in weight, simple in structure, has a high stowage ratio, high deployment reliability, and offers good application prospects for both small-aperture and several-meter large-aperture deployable antennas. Currently, the application of this type of deployable reflector mainly faces two challenges: ensuring the reliability of stowage and deployment strategies for large-deformation wrapping, and achieving and maintaining surface accuracy of the flexible wrap-rib reflector. This paper proposes a CFRP lenticular tube wrap-rib reflector scheme, and its stowage and deployment performance, as well as surface accuracy, were analyzed and tested.MethodsFirstly, a 3 m aperture wrap-rib reflector scheme for X-band was proposed, which includes the central hub, wrap-ribs, metal mesh, side cables, and the locking and unlocking device. The wrap-ribs were made of lightweight, high-strength, and high-stiffness CFRP lenticular tubes, and the [45°/-45°/-45°/45°] lay-up and section design were achieved using prepregs with a single layer thickness of 0.05 mm. To ensure the installation accuracy and deployment rigidity of the wrap-ribs, they were fixedly connected to the central hub. In order to solve the problem of high stress in the root area of the wrapped wrap-ribs, a method of setting a wrapping guide on the root area of the wrap-ribs was proposed. A finite element model was established based on the material parameters obtained from the tensile test, and the stress during the wrapping process of a single CFRP lenticular tube with a wrapping guide was analyzed using the explicit dynamic method. Secondly, according to the requirements of the X-band, the surface accuracy of the 3-meter aperture reflector was estimated using an approximate theoretical formula. The focal length-to-aperture ratio of the reflector and the number of wrap-ribs were selected. Due to the low stiffness of the wrap-rib reflector, the wrap-ribs deform to a certain degree during the forming process of the reflector, and the back-pillow effect appears in each sector mesh. Both of these factors affect the surface accuracy of the reflector. To solve this problem, the shape of the flexible wrap-rib reflector was determined through form-finding analysis. The shape of the lenticular tube wrap-rib was optimized by combining the form-finding analysis of the flexible reflector with the genetic algorithm. Finally, a reflector prototype was designed and assembled, and the deploying test, fundamental frequency test and surface accuracy measurement were carried out.Results and Discussions Adding a wrapping guide to the root area of CFRP lenticular tube wrap-rib can prevent excessive wrapping stress in this area and improve the wrapping performance of the wrap-rib reflector. The focal length-to-aperture ratio of the reflector is 0.55, the number of wrap-ribs is 36, and the RMSE value of the estimated surface accuracy calculated by the theoretical formula is 0.89 mm, which meets the application requirements for X-band. When the upper edge curve of the wrap-rib of the reflector lies on the design paraboloid, the surface accuracy of the reflector after form-finding analysis is 1.51 mm, which is significantly higher than the 0.89 mm calculated by the theoretical formula. This discrepancy arises because the elastic deformation of the wrap-ribs and the back-pillow effect of the metal mesh cause the metal mesh to deviate from its initial position after the form-finding analysis of the flexible wrap-rib reflector. Taking the root of the wrap-rib as the origin, the curve equation of the wrap-rib after optimization is <inline-formula><alternatives><math xmlns:mml="http://www.w3.org/1998/Math/MathML" id="M1"><mi>z</mi><mo>=</mo><mn mathvariant="normal">0.000148</mn><msup><mrow><mi>x</mi></mrow><mrow><mn mathvariant="normal">2</mn></mrow></msup><mo>+</mo><mn mathvariant="normal">0.0359</mn><mi>x</mi></math><graphic specific-use="big" xmlns:xlink="http://www.w3.org/1999/xlink" xlink:href="alternativeImage/30D0F351-5FEC-4cd7-9CCF-CA71966FC3ED-M001.jpg"><?fx-imagestate width="28.70199966" height="2.28600001"?></graphic><graphic specific-use="small" xmlns:xlink="http://www.w3.org/1999/xlink" xlink:href="alternativeImage/30D0F351-5FEC-4cd7-9CCF-CA71966FC3ED-M001c.jpg"><?fx-imagestate width="28.70199966" height="2.28600001"?></graphic></alternatives></inline-formula> (0 mm ≤ x ≤ 1410 mm), and the surface accuracy of the reflector is 0.78 mm, which is obviously better than the 1.51 mm before the shape optimization of the wrap-rib. By optimizing the shape of the wrap-rib, the surface accuracy of the reflector was effectively improved. The mass of the wrap-rib reflector prototype is about 6 kg, and the stowage size is 0.7m × 0.7m × 0.15m. It took about 6 seconds from the time the Dyneema rope was fused until the reflector was fully deployed. The deployment test verified both the stowage mode of the CFRP lenticular tube wrap-rib reflector and the deployment mode driven by the elastic energy of the wrap-ribs. At the same time, the feasibility of the proposed stowage tool and the locking and unlocking device was also verified. The measured fundamental frequency of the deployed reflector prototype is about 1.69 Hz, indicating good overall rigidity. In the surface accuracy measurement, the best self-fitting paraboloid of condition 1 was taken as the reference. The difference in surface accuracy between after installation and after one stowage and deployment is minimal, and it is close to the theoretical design value. After four deployments and three days of placement, the surface error increases slightly but remains below the design target value of 1 mm. The reflector prototype's surface has basically achieved the design goal for surface accuracy. The surface accuracy measurement test results show that the reflector prototype exhibits stable surface accuracy, although the surface accuracy of the reflector decreases slightly after long-term stowage and multiple stowage and deployment cycles.ConclusionsThe results show that the CFRP lenticular tube wrap-rib reflector scheme has the advantages of a simple structure, light weight, high storage ratio, and good overall rigidity. The wrapping guides and the locking and unlocking device contribute to improving the reliability of stowage and deployment. By optimizing the shape of the wrap-rib, the flexible wrap-rib reflector can achieve good and stable surface accuracy. The CFRP lenticular tube has the characteristics of light weight, easy wrapping, and high rigidity after deployment, making it an important option for selecting wrap-ribs in wrap-rib reflectors. Further research should be carried out in the future on the reflector performance under multiple stowage and deployment cycles, long-term storage, and on-orbit environments, as well as the maintenance of surface accuracy.http://jsuese.scu.edu.cn/thesisDetails#10.12454/j.jsuese.202400644wrap-ribreflectordeployable antennaCFRP lenticular tubesurface accuracyprototype verification |
| spellingShingle | ZHANG Han YAN Zhongxi XIANG Ping WU Minger Design and Prototype Verification of a 3-meter Aperture Wrap-rib Reflector 工程科学与技术 wrap-rib reflector deployable antenna CFRP lenticular tube surface accuracy prototype verification |
| title | Design and Prototype Verification of a 3-meter Aperture Wrap-rib Reflector |
| title_full | Design and Prototype Verification of a 3-meter Aperture Wrap-rib Reflector |
| title_fullStr | Design and Prototype Verification of a 3-meter Aperture Wrap-rib Reflector |
| title_full_unstemmed | Design and Prototype Verification of a 3-meter Aperture Wrap-rib Reflector |
| title_short | Design and Prototype Verification of a 3-meter Aperture Wrap-rib Reflector |
| title_sort | design and prototype verification of a 3 meter aperture wrap rib reflector |
| topic | wrap-rib reflector deployable antenna CFRP lenticular tube surface accuracy prototype verification |
| url | http://jsuese.scu.edu.cn/thesisDetails#10.12454/j.jsuese.202400644 |
| work_keys_str_mv | AT zhanghan designandprototypeverificationofa3meteraperturewrapribreflector AT yanzhongxi designandprototypeverificationofa3meteraperturewrapribreflector AT xiangping designandprototypeverificationofa3meteraperturewrapribreflector AT wuminger designandprototypeverificationofa3meteraperturewrapribreflector |