IOP PUBLISHING SMART MATERIALS AND STRUCTURES Smart Mater. Struct. 18 (2009) 065012 (8pp) doi:10.1088/0964-1726/18/6/065012 Shape morphing hinged truss structures A Y N Sofla1 , D M Elzey2 and H N G Wadley2 1 Department of Mechanical and Industrial Engineering, University of Toronto, Toronto, Canada 2 Materials Science and Engineering Department, University of Virginia, Charlottesville, VA, USA E-mail: [email protected] Received 25 November 2008, in final form 26 February 2009 Published 6 May 2009 Online at stacks.iop.org/SMS/18/065012 Abstract Truss structures are widely used for the support of structural loads in applications where minimum mass solutions are required. Their nodes are normally constructed to resist rotation to maximize their stiffness under load. A multi-link node concept has recently been proposed that permits independent rotation of tetrahedral trusses linked by such a joint. High authority shape morphing truss structures can therefore be designed by the installation of linear displacement actuators within the truss mechanisms. Examples of actuated structures with either linear or planar shapes are presented and their ability to bend, twist and undulate is demonstrated. An experimental device has been constructed using one-way shape memory wire actuators in antagonistic configurations that permit reversible actuated structures. It is shown that the actuated structure displacement response is significantly amplified by use of a mechanically magnified design. (Some figures in this article are in colour only in the electronic version) deployable actuated structure [8]. Although VGT structures were originally conceived as the longitudinal repetition of an octahedral truss module [9], tetrahedral truss units were also used in later designs [10]. The application of VGTs in robotic manipulator arm is arguably the first shape morphing truss structure [11]. Such a shape morphing truss structure is different from a one time deployable structure that is unfolded from its initial (packed) form to a final end state configuration. Shape morphing structures are required to reversibly change shape on demand upon application of a suitable stimulus. Several groups have explored the development of shape morphing truss structures. Haftka and Adelman [12] and Matunaga and Onada [13] showed that high precision control of parabolic tetrahedral truss structures could be achieved by replacing some of the truss members with actuators. These actuated trusses were able to precisely compensate structural changes resulting from launch loads or during operations in a space environment. They identified optimal placements for the actuators. Salama et al used the combination of lead screws and piezo-actuators to experimentally demonstrate shape control of an erectable, doubly curved tetrahedral truss structure [14]. More recently, Gullapalli et al proposed an alternate approach to achieve optical quality space mirrors by using piezoelectric inchworm micro-actuators [15]. 1. Introduction An ideal space truss is defined as a three-dimensional system of bars connected at their nodes by frictionless hinges or joints which is subjected to forces applied only at the joint centers [1]. The conventional fixed shape space trusses consisted of tetrahedral truss units, which provide high stiffness and strength to weight. They can be designed as doubly curved structural systems such as the roof of the Eden Project’s structure [2] and Buckminster Fuller’s geodesic dome in Montreal [3]. The high specific stiffness of space trusses also makes them well suitable for large space structures [4], where the high cost of orbital insertion drives the design of mass efficient concepts [5]. Shape morphing structures can be fabricated from truss structures by replacing some of the trusses with linear displacement actuators. Such actuated trusses, also known as adaptable trusses, have been proposed for deployable truss structures which are transported in a tightly packed form and then deployed [6]. Onoda et al proposed a twodimensionally deployable ‘hexapod’ truss structure, which could be replicated in two dimensions to create a parabolic truss structure [7]. Variable geometry truss (VGT) structures have also been proposed by Miura and Furuya as a type of 0964-1726/09/065012+08$30.00 1 © 2009 IOP Publishing Ltd Printed in the UK Smart Mater. Struct. 18 (2009) 065012 A Y N Sofla et al The doubly curved truss structures proposed for antenna or mirror support are statically indeterminate. As a result any length change of a truss member results in the development of states of self-stress within the structure. Actuators in such structures therefore do significant work against the structure leading to sometimes significant inefficiencies. Recently Hutchinson et al proposed and analyzed a class of planar, pin-jointed trusses based on a combination of tetrahedral and planar Kagome (basket weave) truss structures in which some truss members were replaced with linear actuators [16, 17]. These statically determinate actuated structures promised higher authority actuation compared with previous designs. Experimental efforts by dos Santos et al led to Kagome based truss systems capable of significant bending and twisting of the structure using linear actuators [18]. In an alternate approach to create shape changing truss structure for shape morphing of aircraft wing, Deepak et al deigned a tendon actuated compliant structure in which actuation by pulling on one set of tendons while controlling the release of another creates the desired deformations. Six nodded octahedral unit cell with diagonal tendon actuation were used for bending the structure [19]. The shape morphing truss structures described above have utilized conventional actuators and rigidly connected trusses. They result in often heavy and sometimes bulky structures that are difficult to miniaturize. The use of rigid nodes leads can lead to premature failure (by fatigue) in heavily loaded systems. Shape memory alloy (SMA) actuators can be used as an alternative to conventional electromechanical actuation. They exhibit a large recovery stress (several MPa) and relatively large strain recovery (up to 7%) [20] when heated above a critical transformation temperature. Dunlop and Garcia used SMA actuators to deform Stewart platform type structures [21]. The platform links were replaced by bowlike components with SMA wires as the bowstring. Heating the SMA caused contraction of the wire and the elastic curved components to retract. Several of these Stewart platforms could then be stack to create a shape changing truss arm [21]. Here we describe an approach to convert statically determinate trusses to shape morphing truss structures by the replacement of the struts with linear displacement actuators. The shape morphing truss structure is capable of bending, twisting and undulating deformations. The structure consists of tetrahedral truss unit cells, which are connected using a spherical freely rotating joint [22]. The joint provides a means for connecting several struts at a node while ensuring sufficient rotational freedom. Both linear (beam) and planar (plate) designs are illustrated. A design for infinitely large planar mechanisms is developed for potential use as shape morphing surface. At the end, the application of one-way shape memory alloys as linear actuators is discussed. To create reversible actuation the SMA actuators are arranged in an antagonistic manner. A test structure which combines mechanical amplification with reversible antagonistic actuation has been constructed to validate the approach. The rotation angles of a NiTi actuated truss unit cell are predicted and compared with the measured responses of the test structure. The shape morphing trusses can be replaced as Figure 1. A 1-DOF hinged tetrahedral truss (HTT) is a mechanism consisting of two tetrahedral trusses with one shared truss member (a). A high authority morphing hinged truss (MHT) can be formed by the connection of the top of pyramids in a HTT with a linear displacement actuator (b). the reconfigurable backbone structures of existing conventional structures to convert them to adaptive structures. Examples include, but are not limited to, buildings and infrastructure, vehicles and aerospace structures. 2. Design and analysis 2.1. Basic concepts A simple one degree of freedom mechanism, referred to here as a hinged tetrahedral truss (HTT) structure can be created by a combination of two pin-jointed tetrahedral truss units, figure 1(a). It can be seen that the triangular bases of the two tetrahedral truss pyramids share a truss member about which they are free to rotate by means of rotational joints (nodes). The HTT allows a pair of tetrahedral trusses to freely rotate about their shared truss. Maxwell’s stability criterion [23] enables determination of the number of inextensional mechanisms, M , of such a pinjointed structure in terms of the number of non-foundation joints ( j ) and non-foundation truss members (b ). The threedimensional form of the criterion applicable to the tetrahedral system shown in figure 1(a) can be written: M = 3 j − b. (1) For the HTT structure shown in figure 1, b = 8 and j = 3 (one of the base triangles consisting of three nodes and three bars is the foundation). For the design shown in figure 1(a), M = 1 which denotes a kinematically indeterminate structure (or mechanism) with one degree of freedom. Conventional space truss structures are usually connected with rigid nodes, which restrict rotations of the truss members at the nodes. They do not satisfy the pin-joint requirements of a statically determinate structure. A hexa-pivotal joint (HP joint) design was earlier developed as a solution to this issue [22]. The use of HP joints as the revolute nodes of the HTT, figure 1(a), would allow rotation of the tetrahedral trusses about their common truss member, and allows the geometry to act as a mechanism prior to the attachment of linear actuators. 2 Smart Mater. Struct. 18 (2009) 065012 A Y N Sofla et al Figure 3. A planar morphing hinged truss (PMHT) applies three linear actuators and a closed chain hexa-pivotal joint. same amount, results in pure bending of the truss upward, figure 2(b), while the alternating contraction and extension of the actuators results in the pure twisting of this linear morphing hinged truss (LMHT) structure, figure 2(c). Such linear truss actuators could be used as a space truss manipulator, a robotic arm and other applications. The basic HHT (figure 1) can also be repeated in two dimensions to create a planar truss mechanism, figure 3. This hexagonal structure has three degree of freedom (b = 27, j = 10, M = 3 from equation (1)). Any arbitrary three adjacent pairs of pyramid tops (the top node of the tetrahedral) can therefore be connected by linear actuators (dashed lines) to create a planar morphing hinged truss (PMHT). However, the use of more than three actuators results in the states of self-stress upon the extension/contraction of the actuators and significantly reduces the device authority. On the other hand, using two or less actuators leads to kinematically indeterminate structures (mechanisms). A closed chain hexa-pivotal joint is used at the center of the device, which connects 12 truss members and provides rotational freedom at central node. It has been shown that the closed chain HP joint posses three degree of freedom and is therefore suitable for converting a 3-DOF hexagonal structure to a PMHT [22]. Several hexagonal structures can be assembled in planar patterns to create larger planar truss mechanisms, figure 4. Each tetrahedral in figure 4 is represented by its pyramid base (the out of plane truss members of the tetrahedral are not shown for clarity). Two patterns, to create a plate-like structure are proposed in figure 4. In the ‘a-pattern’, each internal hexagon is surrounded by six other hexagons. The smallest ‘a-pattern’ structure is therefore a seven hexagon HHT. We refer to such a mechanism as an ‘a-pattern’ mechanism with k = 1 (because the central hexagon is surrounded by only one ring of hexagons). Such truss mechanism posses 15 DOF (equation (1), b = 195, j = 70, M = 15). Larger truss mechanisms can be created by the addition of extra rings of hexagons. In general, the DOF of an ‘a-pattern’ truss mechanism can be determined from Maxwell’s stability Figure 2. (a) A linear morphing hinged truss (LMHT), (b) LMHT undergoes bending by the contraction of all the actuators, (c) LMHT undergoes twisting by the alternate contraction and extension of the actuators. The hexa-pivotal joint consists of spherical shell elements (links), which can rotate with respect to each other without interference. A pivot pin passes through the common center of curvature of each couple of neighboring links. To ensure the links remain in sliding contact, they are fabricated from spherical shells where the outer radius of the smaller sphere is equal to the inner radius of the larger one, figure 1(a). Connecting the pyramid tops of the single degree of freedom HTT in figure 1(a) with a strut, results in a statically determinate truss (b = 9, j = 3 therefore M = 0 from equation (1)), which means if an external load is applied to the structure, the force in every truss member can be determined from the equations of mechanical equilibrium at the nodes. Such a structure is also kinematically determinate since the location of the joints can be uniquely determined. If the pyramid tops are connected with a linear displacement actuator, figure 1(b), the resulting statically and kinematically determinate truss structure can exhibit high authority shape morphing. Such actuated truss structures are called morphing hinged trusses (MHT) here. The basic HHT in figure 1(a) can be linearly replicated to create linear truss mechanisms. In figure 2(a) eight tetrahedral are hinged at their bases. For this case, b = 38, j = 15, and therefore M = 7 (from equation (1)). Seven linear actuators (denoted by dashed lines in the picture) sequentially connect the pyramid tops to form an actuated truss beam. The truss beam is capable of bending and twisting as well as a combination of both those deformations. For instance, simultaneous contraction of all the linear actuators by the 3 Smart Mater. Struct. 18 (2009) 065012 A Y N Sofla et al Figure 5. A planar morphing hinged truss (PMHT) consisting of 18 actuators and 36 tetrahedra. It is apparent that for all nonzero k , the average number of DOF’s per tetrahedral for the b-pattern is larger than for the a-pattern. The parabolic increase in the DOF for the b-pattern also indicate that if an infinite plane is filled with the ‘b-pattern’ (k → ∞) then the average DOF per tetrahedral approaches 0.25 or equivalently 1.5 DOF per hexagon. Therefore an infinitely large ‘b-pattern’ truss mechanism can be converted to a statically determinate actuated truss by using an actuator density of three actuators per two hexagons. Alternatively if an infinitely large plane is filled with the ‘a-pattern’ (k → ∞), then the average DOF per tetrahedral, approaches zero that means the structure is too rigid. The large total number of degrees of freedom for the ‘b-pattern’ suggests that the pattern can be used to design precision shape controlled actuated truss structures such as antennas. A first order (k = 1) ‘b-pattern’ PMHT, is shown in figure 5. The actuators in the figure are represented with the dash lines. There are a total 18 actuators in the PMHT in figure 5, because the DOF for the corresponding truss mechanism is 18, equation (3). The actuators are assembled to connect the pyramid tops of 18 pairs of adjacent tetrahedra. The 18 locations can be any arbitrary selection of the total 42 distinct available locations provided no more than three actuators are placed in each hexagon. This restriction is enforced because the closed chain hexa-pivotal joint at the center of the hexagons has three degrees of freedom and therefore using more than three actuators will result in the local states of self-stress [22]. The location of the actuators can be selected to fit the targeted shapes for the shape morphing structure. Figure 6(a) demonstrates the unfolding of the first order PMHT to a flat shape and then its deformation to an undulating shape, figure 6(b). The tetrahedral in the figure are represented by colored triangles for visibility and the actuators are not shown. The sequence can depict unfolding a deployable space truss. Figure 7 shows a second order ‘b-pattern’, k = 2, with 60 DOF which deforms from a flat structure to a cup shape. Application oriented arbitrary shapes can be achieved by the control of the actuators displacement and location. Figure 4. Large aspect ratio PMHT can be designed by the assembly of several hexagons with different patterns. The b-pattern provides greater total degrees of freedom. criterion and is given by: DOF = 12k + 3. (2) The DOF of the structure identify the total number of actuators, which must be assembled to convert the mechanism to a statically determinate planar morphing tetrahedral system of trusses. A second, ‘b-pattern’ arrangement, figure 4, can be created by leaving hexagonal holes in the ‘a-pattern’ mechanism to achieve a larger DOF per hexagon. The total DOF of the ‘b-pattern’ can again be determined from Maxwell’s stability criterion; DOF = 9k 2 + 15k − 6. (3) The truss order (k ) is shown for both the ‘a’- and ‘b’-patterns in figure 4. Comparison of the average degrees of freedom per tetrahedral (equivalently the base triangles in figure 4) for the two patterns, equations (4) and (5), reveals that the b-pattern has a larger total number of degrees of freedom; DOF per tetrahedral for pattern (a): = 12k + 3 (4) 6 (3 k 2 + 3 k + 1 ) DOF per tetrahedral for pattern (b): = 9k 2 + 15k − 6 . (5) 36k 2 4 Smart Mater. Struct. 18 (2009) 065012 A Y N Sofla et al Figure 8. One-way shape memory alloy actuators can connect the pyramid tops of a hinged bi-pyramid to create a reversible truss. The contraction of actuator 1 by heating rotates the cell about a revolute joint by an angle θ and causes the extension of actuator 2, and vice versa. linear displacement [20]. However, a biasing force is needed to restrain the contracted actuator and therefore complete a reversible actuation cycle. We have previously used an antagonistic approach [24] to create the biasing force, and successfully designed and fabricated several actuated beams and devices [25]. Here we exploit the implementation of the method in the truss mechanisms. The antagonistic approach requires that the basic HTT, figure 1, be modified to accommodate a pair of countering SMA actuators. Hence, mirror tetrahedral trusses are assembled on the opposite sides of the original pyramid base, creating hinged bi-pyramids, figure 8. The strain actuation Figure 6. The shape morphing of a ‘b-pattern’ PMHT with 18 actuators (not shown). (a) Unrolling to a planar shape. (b) Undulating from a flat shape. 2.2. Antagonistic shape memory actuation One-way shape memory alloy (SMA) wire and ribbon made from equi-atomic NiTi alloys can be used as the linear displacement actuator in the design of MHT’s. The resistive heating can be accomplished by passing electric current through a strained one-way actuator to create contractile Figure 7. The undulating deformation of a second order b-pattern PMHT, k = 2 with 60 actuators (not shown). 5 Smart Mater. Struct. 18 (2009) 065012 A Y N Sofla et al Figure 9. A shape memory actuated antagonistic hinged bi-pyramid. shown in figure 9 were made. Near equi-atomic NiTi wires were used in this study to connect the pyramid tops, figure 9. Several samples, with different pre-strains were fabricated. The NiTi wire diameter was 0.4 mm. The truss members were selected to have high plastic buckling resistance and were fabricated from stainless steel precision tubes with outside diameters of 1.47 mm and thickness of 0.2 mm. The H–P joint links were 1.0 mm thick with the dimension of 10 mm × 10 mm and 12 mm × 10 mm (the outer links are wider), figure 1(b). The H–P links were machined from stainless steel. The NiTi wire was passed through the tubes and connected at the H– P joint to mechanically magnify the recovered shape memory strain of the NiTi wires. Parts of the NiTi wires which pass through the tubes were electrically insulated by Teflon sleeving. Mechanical fasteners were used to firmly connect the NiTi wires to the truss tubes at the H–P joints. The rotation of the bi-pyramids about the shared truss member, figure 8, was measured for different shape memory pre-strain by actuated (deformed) bi-pyramid’s picture. The camera was placed along the shared strut of the bi-pyramid to accurately record the rotation angle. The rotation angles were later measured from the photos. A first order ‘b-pattern’ planar morphing hinged truss (PMHT) is also designed and fabricated. The prototype unit cells shown in figure 8 are used in the design. The PMHT includes 18 pairs of actuators and total 36 bi-pyramids. Several different shapes are attained for the PMHT by actuating different sets of actuators. capability is then imparted to the antagonistic flexural unit cell (AFC) [24] by mechanically stretching at least one of the two opposing actuators connecting the bi-pyramid tops. The initial pre-straining should take place at low temperature when the SMA is in its martensitic or R-phase state [25] prior to assembly to the cell. This pre-strain in actuator 1 in figure 8 is denoted ε1s . That in actuator 2 is ε2s . Upon heating the prestrained actuator, it will begin to contract and cause rotation of the bi-pyramids about their shared pivoting truss. This rotation requires extension (straining) of actuator 2 and results in a remnant strain, ε , in actuator 1. Given a pre-strain value, and cell geometry, the cell rotation angle, θ , can be calculated and is given by [24]: 2(1 + ε − ε1s )2 −1 −1 θ = 2 tan (L/H ) − cos 1 − (6) 1 + (H /L)2 where, L is the SMA actuator length in the initial configuration (prior to the activation of the assembled cell), H is the distance between the tops of each bi-pyramid, figure 8. The strain, ε, refers to the strain in actuator 1 measured with respect to the original length (prior to the pre-straining) of the actuator. Note that, for relatively small rotation angles (smaller than ten degrees), the strain developed in actuator 2, can be related to the strain in actuator 1 [25]; Strain in actuator 2 = (ε1s + ε2s ) − ε. (7) If only one of the actuators, say actuator 1, is pre-strained then equation (7) becomes; Strain in actuator 2 = ε1s − ε. 4. Results and discussion (8) Heating the top NiTi wire, figures 8 and 9, above its martensite finish temperature, Af , results in the upward rotation of the cell to an active equilibrium position [25]. Upon cooling below the martensite start temperature, Ms , the top NiTi wire undergoes a martensitic transformation which results in the extension of 3. Experimental assessments To determine the relationship between the rotation angle of the bi-pyramids to the shape memory pre-strain, the test structures 6 Smart Mater. Struct. 18 (2009) 065012 A Y N Sofla et al also observed in this study that the shape recovery of NiTi wires is similar to the ribbons and therefore the data can be used to estimate the equilibrium rotation angles of the truss unit cell. The mechanical amplification method requires the SMA wires be attached to the HP joint rather than the pyramid tops. The recovered strain, ε , must therefore be multiplied by the amplification factor which is defined by the ratio of the length of the wire divided by the distance between the pyramid tops. For the prototype, figure 8, this amplification factor was determined to be 3.2 (80/25 mm). The active and inactive rotation angle as a function of prestrain have been determined [25] and are plotted in figure 10. In addition, the responses of prototypes fabricated from actuators with 2.5%, 4%, 5%, 6%, and 7% pre-strains are marked in the figure for comparison. The figure shows that there is good agreement between the measured and predicted deformations for smaller pre-strains. However the measured ranges are smaller than the predicted values at the larger pre-strains probably due to the frictional effects, which have been ignored in the analysis. The mechanical amplification method used in this design has made large rotation angle of over 10◦ feasible. The promising deformations achieved in this design from relatively small strain recovery of restrained SMA actuators (less than 4%) makes the method suitable for high authority shape morphing applications. The ‘b-pattern structure has also been investigated. Figure 11 shows the symmetric deformations of a first order ‘b-pattern’ PMHT. The bending of the device is shown in figure 11(a), the twisting in figure 11(b) and undulating in figure 11(c). Local deformation resulted from the weight of the truss is visible at the attaching point of the truss to the vice. Figure 10. Rotation angle of the actuated bi-pyramids at mechanical equilibrium. the wire due to the de-twinning and causes the downward rotating relaxation of the unit cell. At the mechanical equilibrium (inactive equilibrium) further displacement ceases. The new rotation angle of the cell remains unchanged without requiring additional power and is therefore suitable for long term applications. The heating of the bottom actuator above Af later in the cycle results in the contraction of the heated wire (shape recovery) to a second active equilibrium state resulting in a further downward rotation. The difference of the two active rotation angles is the active rotation range of the cell and is the maximum deformation that the unit cell can achieve. Cooling the bottom SMA wire in turn relaxes the unit cell and the bi-pyramids slightly rotate upward to a new inactive configuration. The inactive rotation range is the maximum attainable deformation range for the unit cell at low temperature. The rotation angle depends on the shape memory pre-strain in the top wire, or actuator 1, ε1s , the cell geometry and the recovered strain, ε , equation (6). The recovered strain of the antagonistic actuators as a function of shape memory pre-strain for ribbons of identical NiTi alloy has been measured and analyzed [25], and it was 5. Conclusion Hinged truss mechanisms can be designed by using a novel spherical–pivotal joint (H–P joint). Several truss members can be connected at the truss nodes and freely rotate about revolute truss members of the hinged trusses. The assembly of a number of actuators equivalent to the total degree of freedom of the hinged truss mechanism can create high authority planar morphing hinged trusses (PMHT) with possible applications Figure 11. Deformations of a prototype PMHT. (a) Bending, (b) twisting and (c) undulating. 7 Smart Mater. Struct. 18 (2009) 065012 A Y N Sofla et al such as antenna supports or shape changing constructions. One-way shape memory wires can also be used to actuate the hinged trusses. An antagonistic hinged truss mechanism is designed to allow the shape memory alloy actuation of the PMHTs. Using SMA wires longer than the original intended actuator length has resulted in the significant amplification of the response of the PMHT. 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