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Design of the Deployment Mechanism of Solar Array on a Small Satellite

Article · January 2013

DOI: 10.12691/ajme-1-3-2

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American Journal of Mechanical Engineering, 2013, Vol. 1, No. 3, 66-72
Available online at http://pubs.sciepub.com/ajme/1/3/2
© Science and Education Publishing
DOI:10.12691/ajme-1-3-2

Design of the Deployment Mechanism of Solar Array on

a Small Satellite
M. G. El-Sherbiny1, A. Khattab1, M.K. Kassab2,*
1
Mechanical Design and Production Eng., Cairo University, Giza, Egypt
2
Structure Department, National authority for Remote Sensing & Space Sciences (NARSS), Cairo, Egypt
*Corresponding author: [email protected]

Received December 20, 2012; Revised May 06, 2013; Accepted May 07, 2013
Abstract This paper presents analytical simulation of drag braking during deployment of a solar array system of a
small satellite within the space environment, and helps the designer to detect problems during ground testing. The
deployment mechanism (DM) is modeled by using Mechanical Desktop (MDT) software and analyzed by using
Finite Element Analysis Package (ANSYS 11). Design and Stress analysis of DM is performed at the most critical
points during its functioning. Several finite element analysis models were considered to verify the DM integrity.
These analyses were correlated with static, modal and random vibration testing. The present work can help in
checking the survival of the mechanism under realistic operating conditions and makes sure that it will perform well
after an orbit insertion of the satellite.

Keywords: satellite, deployment mechanism, shoe brake, solar Array, finite element, modal analysis

The designed brake has to be checked and tested

accurately before the prototype is made available [4].
1. Introduction In the present work the DM is modelled by using
Mechanical Desktop (MDT) software and then analyzed
Today’s engineering design needs to manage the by Finite Element Analysis Package (ANSYS 11).
conflicting goals, improving performance while reducing Simulation analysis was made to describe the dynamic
developing time and costs. In this context designers behavior of the mechanism structure and to predict its
utilized the solar energy as clean renewable source for natural frequencies and structure response to the worst
powering small satellites. Solar arrays of considerable case of Launch Vehicle (LV) loads through static, modal
surface area are required to provide enough power for the and random vibration analysis [5].
safe payload functioning and for the computer and the Mechanical structure can resonate, where small forces
communication systems, [1]. Figure 1 shows a schematic can result in significant deformation, and damage can be
drawing of the satellite with the solar arrays [2]. induced in the structure. Resonant vibration is mainly
Innovative designs included foldable solar arrays to caused by an interaction between inertial and elastic
minimize size and space requirement on the launching deformations of the materials within a structure. To better
vehicle. Self actuated deployment mechanisms utilized the understand structural vibration problems, the resonant
stored energy in a torsion spring to drive the solar arrays frequencies of the structure have to be identified. Modal
during the unfolding phase after orbital insertion. In such analysis is recognized as a technique in finding the modes
cases the motion has to be controlled by drag braking to of vibration of machines, and mechanisms [6].
reduce or eliminate the shock loading at the end of the
stroke. Drag brake should be of minimum size and weight
but can absorb and dissipate energy enough to make 2. Structure and Model Description
gradual deployment and smooth motion until the
mechanism gets to rest at the end of the stroke, without The DM is intended for fastening of solar panel to the
shock loadings or reactions. A special small drum brake, satellite body, turning the solar panel into the working
with frictional shoes which are forced in contact with the position and keeping it in this position during operation in
drum under a compressive spring force, was designed for orbit. Once the Satellite is in orbit, the Solar Arrays are
this particular purpose [3]. Figure 2 shows an isometric deployed to function. Therefore, Mathematical Model of
drawing of the brake assembly. DM is constructed and analyzed using finite Element
The brake has an estimated weight of 0.350Kg and is Computer Package (ANSYS 11) to minimize the cost of
able to deploy the solar arrays in 2 to 3 seconds depending making prototypes and the time in trial and error practices.
on the realized coefficient of friction of 0.5 in normal Figure 3 shows the MDT model of the designed DM brake
atmosphere and 1.0 in space environment at an altitude of assembly to eject the folded SA and to control its
768Km. deployment under drag braking. The finite element
package provides a library of structure elements, such as
 American Journal of Mechanical Engineering 67

beams, shells, and solid elements. The DM is modeled by and appropriate boundary conditions to describe the
connecting elements together within the geometrical physical constraints.
constraints, taking into consideration material properties,

Figure 1. Top view of the satellite with four solar arrays

Figure 2. Assembly of shoe brake Figure 3. Isometric 3D view of the model

68 American Journal of Mechanical Engineering

Forces and moments obtained from solar array

mechanism and structural analysis are given in [7].
Fx = - 1.291e-002N, Fy = - 5.33e-004 N,
Fz = - 1.651e-002N. Mx = 7.28 e-003N m,
My = - 5.795 e-003N m Mz = 5.745 e-003N m.
FE analysis of DM is performed to make sure that the
DM structure will withstand the loads at the stoppage
point. It is recommended to run modal analysis to make
sure the natural frequencies of SA will not coincide with
the DM ones.
ANSYS 11 FE package is used to make the design
analysis and verify the design [8]. The method uses a
complex system of points (nodes) which form a grid or a
mesh. Fine mesh is used to model fine geometrical details
as well as closely approximate the localized stresses and
strains in areas of steep gradients or of high stress
concentrations. The model represents the assembly of all
components and parts of the mechanism linked together Figure 4. Tetrahedral mesh of the brake mechanism
and exposed to maximum loading conditions.

Figure 5. Total Deformation within the mechanism

Using relevance of 100; and relevance center medium,

2. 1. Mesh Generation one gets:
No. of elements: 595160;
Tetrahedral elements are used as shown in Figure 4. No. of degrees of freedom (No. of Nodes): 1249356,
When using high relevance of 100, and fine relevance whilst using relevance of 50; and relevance center medium,
center, the meshing leads to huge sizable number of nodes gives:
and elements. But when simplifying relevance to 60 or 50 No. of elements was: 90914;
and selecting a relevance center of medium or coarse, the No. of degrees of freedom (No. of Nodes): 194640,
meshing problem can be smoothly solved.
 American Journal of Mechanical Engineering 69

Therefore the later case is more appropriate to minimize

truncations and round off errors. Figure 4 shows the mesh
design of the DM brake assembly.

2.2. Materials
The materials are selected to meet the requirements of
each individual component. Structural steel was selected
for parts: rotating shaft, screws, and joints. AISI 4130
steels and 304 stainless steels were used for drums, Gray
cast iron is also used for brake shoes, Aluminum alloy
AMG6 is used for movable bracket, housing cage and
friction arms, whilst other commercial aluminum alloys
were used for guiding bushes, and Piano wire spring DIN
17223D is used for spring elements. The mechanical,
thermal and physical properties of these materials as
employed in the present work are given in appendix I. Figure 7. Equivalent Stress distribution (Von-Misses)

3. Static Analysis
4. Modal Analysis of DM
The objective of static loading is to define the resulting
load distribution, strains and stresses throughout the Modal analysis and testing is used to identify the
structure of mechanism components. When performing vibration modes and their natural frequencies, and to
static analysis under load, static forces and moments are provide the structural matrices, which is required for the
applied to the assembly of the mechanism components. dynamic analysis of the assembly. Thus the basic
The linear static analysis in ANSYS is used to compute structural dynamic data, as obtained accurately from a
stresses, strains and deformations [9]. valid test provides a true identification of the structural
Figure 5 represents the ANSYS static analysis from behavior at the modes of interest. These derived matrices
geometry definition passing through connection definition, are based on the measured contributions of the mass,
meshing the model and up to post processing of the static stiffness and damping properties at the modes of interest,
structural results. It also shows the critical areas of the taking into considerations the actual boundary conditions.
maximum deformation occurs on the movable bracket These data is introduced into a finite element model of the
reaching a maximum computed value as 2,2501e-004 m. structure, for subsequent problem solving, or re-designing
The results indicated that deformations, strains, and the mechanism for better dynamic response [9].
stresses are small and did not threaten the structure of SA Modal analysis was performed to the model of DM
and the movable bracket. using ANSYS 11 software and the model has been solved
Figure 6 shows the critical areas of the highest strain in for the first 5 modes. Figure 8 and Figure 9 show the
the DM, and also shows the locations of applied loads and resulting first two modes of vibration. This analysis is also
the fixed nodal points resembling fixed supports. The used to gain better understanding of DM behavior and
analysis showed that the most critical strain occurs on response to environmental conditions which of course,
housing cage 2,1718e-002m/m. lead to better planning of the experimental testing.
Figure 7 shows the critical regions or the most stressed The normal modes obtained from the FEA for DM
regions in the DM. The analysis showed that the most model before testing, represent fairly reasonable
critical stress occurs on cubic joint and its value is estimation of the DM Eigen frequencies and mode shapes.
2,7544e+008 Pa. Obviously the computed max shear This information is used to plan the real testing; that is, to
stresses were far below the shear strength of the part and determine excitation conditions, shaker locations and
therefore the design was mechanically safe under static accelerometer locations.
loading conditions.

Figure 8. First mode shape of DM structure at fn = 0.25236 Hz

Figure 6. Areas of highly localized strains
70 American Journal of Mechanical Engineering

compression spring with a value of 733.18Pa. These

stresses are far below the material failure limits, do not
form threatening for DM, and implies that DM can
withstand vibration loads well after an orbit insertion of
the satellite.

Figure 9. Second mode shape of DM structure at fn = 0.31372 Hz

5. Random Analysis
Figure 10. PSD Acceleration versus Frequency
The fundamental nature of random vibration are needed
to verify design, develop and produce cost effective and
lightweight mechanisms that are capable of operating in
various environments with high degree of reliability. The
characteristic of random vibration is non-periodic and it
can be considered as a series of overlapping sinusoidal
curves [9,10,11]. In this environment all the exciting
frequencies within a given bandwidth are excited at the
same time.
One of the different types of curves that can be used to
show the random vibration input requirements is the
Power Spectral Density (PSD) curve. Table (1) shows the
PSD data. This is also shown in log-log scale with power
spectral density (G2/Hz) along the ordinate vertical axis
and frequency (Hz) along the horizontal abscissa axis. It
should be noted that acceleration is represented as root
mean square (RMS) and it is the area under the random
Figure 11. Stress distribution on the DM model
vibration curve. Figure 10 shows the shaped random
vibration input curve for the DM model. Deformations occurred under the effect of frequencies
load at all directions (X, Y, and Z) and the resulting
Table (1). PSD Acceleration vs. Frequency deformations due to velocity and acceleration loads did
Frequency Hz PSD Acceleration (m/sec²)²/Hz not represent a threat to any of the DM components.
Figure 12, Figure 13 and Figure 14 show the deformation
10,0 1,0 due to directional displacement, velocity and acceleration
25,0 1,3 along the X axis.

50,0 1,0

80,0 3,1

130,0 1,6

160,0 2,8

190,0 1,2

225,0 2,0

270,0 2,8

310,0 5,0
Figure 11 shows the resulting stresses of DM analysis
and it is seen that stress distribution values have occurred
at scale factor 1 sigma, and probability of 68.3% of the
time at X-axis direction. It also, shows that the maximum Figure 12. Deformation due to displacement of DM mechanism on X
effect of frequencies occurs on Torsion Spring and axis
 American Journal of Mechanical Engineering 71

[4] Friswell, M. I., Mottershead J. E., “ Finite Element Model

Updating in Structural Dynamics” Dept. of Mechanical
Engineering, University of Swansea, Swansea, U.K. Springer,
Solid Mechanics and Its Applications, Vol. 38, P292. 1996.
[5] Shibabrat N., Wrik M., “Experimental Modal Testing for
Estimating the Dynamic Properties of a Cantilever Beam” ,
Department of Civil Engineering , Jadavpur University, Kolkato-
700 032. http://fosonlietne.org/Thought/CA-77.pdf.
[6] Bart B. Wim H. and Jan D.; “Modern Solutions for Ground
Vibration Testing of Large Aircraft”; LMS International, Leuven,
Belgium, SAE International Journal of Aerospace, April, 2009,
Vol. 1, No. 1, pp. 732-742, 2009.
[7] EgyptSat-1 Project, Satellite Preliminary Design. Composition
and main Characteristics, Doc. No. EGS YZH RPT 01400 issue 2.
2007.
[8] ANSYS, Inc. Release 11.0 Documentation for ANSYS.
[9] Sudharsan, M; “Structural Design and Analysis of a lightweight
Composite Sandwich Space Radiator Panel” Msc. Thesis, Office
of Graduate Studies of Texas A&M University, USA, December
Figure 13. Deformation due to velocity on X axis 2003.
[10] Neville F. Rieger; “the Relation between Finite Element Analysis
and Modal Analysis”; Stress Technology Incorporated, Rochester,
New York. 2008.
[11] Fufa, B.; Zaho, C.; and Wensheag, M.; “Modeling and Simulation
of Satellite Solar Panel Deployment and Locking” Information
Technology Journal 9 (3): pp. 600-604, 2010.

Appendix I
Table 1. Properties of Structural Steel
Structural
Young's Modulus 2,e+011 Pa
Poisson's Ratio 0,3
Density 7850, kg/m3
Tensile Yield Strength 2,5e+008 Pa
Tensile Ultimate Strength 4,6e+008 Pa
Thermal
Thermal Conductivity 60,5 W/m· °C
Figure 14. Deformation due to acceleration on the X axis Specific Heat 434, J/kg·
°C

Table 2. Properties of Aluminum Alloy

6. Conclusion Structural
Young's Modulus 7,1e+010 Pa
Linear static analysis of the DM is performed using FE Poisson's Ratio 0,33
analysis on ANSYS software and the deformation and Density 2770, kg/m3
displacement are computed. The modal analysis was Tensile Yield Strength 2,8e+008 Pa
conducted and the first five resonance frequencies (mode Tensile Ultimate Strength 3,1e+008 Pa
shapes) are calculated. Results obtained from Random Thermal
vibration analysis revealed that the maximum stresses Specific Heat 875, J/kg·
°C
occurred on Torsion Spring and Compression Spring with
a value of 733.18Pa. The FE analysis of the proposed Table 3. Properties of Steel Standard AISI 4130
design of the DM for SA of a small satellite showed that Structural
the model survived vibration loads, moments, and forces Young's Modulus 2,e+005 Pa
at operating conditions similar to those expected after an Poisson's Ratio 0,3
orbit insertion of the satellite. The present work also Density 7700, kg/m3
shows that the designed small shoe brake can be used to
control the unfolding and protect the solar panels from Table 4. Properties of Stainless Steel 316
shock loads and damage at the end of the deployment. Structural
Young's Modulus 1,93e+011 Pa
References Poisson's Ratio 0,31
Density 7750,kg/m3
[1] Heylen W., Lammens S., Sas P.,: Modal Analysis Theory and Tensile Yield Strength 2,07e+008 Pa
Testing, Katholieke Universiteit, Leuven, 1997.
Tensile Ultimate Strength 5,86e+008 Pa
[2] Egypt Sat-1 Project, Satellite Preliminary Design. Album of
Drawings. Doc. No. EGS YZH RPT 01801, NARS, EGYPT, 2007. Thermal
[3] Kassab, M. “Design, Analysis, Manufacturing, and Testing of a Thermal Conductivity 15,1W/m °C
Deployment Mechanism for Solar Panel of a Small Satellite“;
Ph.D. thesis, Faculty of Engineering, Cairo University, Egypt, Specific Heat 480,J/kg·
°C
December 2011.
 72 American Journal of Mechanical Engineering

Table 5. Properties of Aluminum Alloy AMG6 Table 7. Properties of Gray Cast Iron
Structural Structural
Young's Modulus 7,1e+010 Pa
Young's Modulus 1,1e+011Pa
Poisson's Ratio 0,33
Density 2770,kg/m3 Poisson's Ratio 0,28
Thermal
Specific Heat 875,J/kg·
°C Density 7200,kg/m3

Table 6. Properties of Piano Wire Steel DIN 17223D Tensile Ultimate Strength 2,4e+008Pa
Structural
Thermal
Young's Modulus 2,06e+011Pa
Poisson's Ratio 0,29 Thermal Conductivity 52,W/m·
°C
Density 7850,kg/m3
Specific Heat 447,J/kg·
°C
Thermal
Specific Heat 450,J/kg·
°C

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