IOP PUBLISHING SMART MATERIALS AND STRUCTURES Smart Mater. Struct. 16 (2007) 1277–1284 doi:10.1088/0964-1726/16/4/040 A rotational joint for shape morphing space truss structures A Y N Sofla, D M Elzey and H N G Wadley Materials Science and Engineering Department, University of Virginia, Charlottesville, VA 22904, USA E-mail: [email protected] (A Y N Sofla) Received 28 November 2006, in final form 10 June 2007 Published 5 July 2007 Online at stacks.iop.org/SMS/16/1277 Abstract A rotational joint is introduced for use in shape morphing or deployable space truss structures. The joint is a chain mechanism comprising up to six pivoted linkages that provide a compact mechanism for the connection of up to six structures at a node. The total number of degrees of freedom for a constrained joint mechanism with six links is found. A closed chain model is then used to determine the angle between the adjacent links as the structure is changed during shape morphing. The limiting pivot rotation angle is established by physical interference and is determined for a model problem. (Some figures in this article are in colour only in the electronic version) 1. Introduction Space truss structures consist of truss members (struts) joined at nodes [1]. The nodes restrict axial movement of the truss and impede truss rotation at the nodes. This rotational resistance could be a significant limitation for actuated truss structures in which some trusses are replaced by linear displacement actuators. To illustrate, consider a simple, tetrahedral threedimensional (3D) truss structure supported on one of its triangular sides by a foundation, figure 1(a). The number of inextensional mechanisms, M , of such a pin-jointed structure is given by Maxwell’s stability criterion, which relates the number of non-foundation joints ( j ) and non-foundation truss members (b) to M [2]. The three-dimensional form of the criterion applicable to the tetrahedral shown in figure 1 can be written: M = 3 j − b. (1) For the pin-jointed truss structure shown in figure 1(a), b = 3 and j = 1 (one of the triangles consisting of three nodes and three bars is the foundation). In this case, M = 0, which defines a statically determinate structure. If an external load is therefore applied to the structure, the force in every strut can be determined from the equations of mechanical equilibrium at the nodes. The structure is also kinematically determinate since the location of the joints can also be uniquely determined. If M has a positive value, the structure is kinematically indeterminate and the location of one or more nodes can then no longer be uniquely determined by the length of the trusses. 0964-1726/07/041277+08$30.00 Removing one of the non-foundation trusses of the statically determinate structure, figure 1(b), results in a structure that behaves as a mechanism with one degree of freedom ( M = 1). Replacing the removed truss with an extensional actuator can restore the static determinacy of the tetrahedral truss structure and allows it to then exhibit shape changing behavior provided the nodes marked 1 and 2 in figure 1(b) have a rotational degree of freedom. Such structures have attracted recent interest for shape morphing applications since they do not develop states of self stress when shape changes are caused to occur by longitudinal deformations of the linear actuator [3]. They are therefore candidates for high authority, shape morphing systems. The very simple statically determinate system shown in figure 1(a) is of limited utility for smart structures. However, Hutchinson et al [4] have identified a 3D kagome ‘plate like’ truss structure in which the trusses are connected by pin joints with no rotational resistance, figure 2. This structure has been converted to a shape morphing truss plate by replacing some of the trusses with linear actuators. Unfortunately the trusses in such space truss structures are connected at nodes by either welding or by mechanical fastening (for example by screwing the trusses to a spherical node) and they are unable to rotate about the node. Deformation of the truss (induced by the actuators) then results in either elastic or/and plastic deformation near these joints. The storage of strain energy at the joints limits the shape morphing capability of the plate and repeated cycling of the © 2007 IOP Publishing Ltd Printed in the UK 1277 A Y N Sofla et al Figure 1. A tetrahedral space truss unit attached on one side to a rigid foundation. (a) A pin-jointed statically determinate truss. (b) Elimination of one truss member changes the structure to a mechanism provided nodes 1 and 2 permit rotational degrees of freedom. Figure 2. Example of a 3D kagome plate for shape morphing plate structure [4]. The welded node construction causes stresses to develop in the trusses during actuation. This limits actuation authority and increases the susceptibility of the structure to failure by fatigue. structure’s shape could lead to premature failure by fatigue. Shape morphing structures of this type could therefore be improved if the trusses were connected using nodes that had a low rotational resistance. In general, connecting more than two moving trusses or linkages to a single joint complicates the mechanical design and associated fabrication processes. For instance, two rods may be connected by a spherical joint with three degrees of freedom. Such ball joints are relatively easy to manufacture and designs are available as spherical bearings. However adding only one more link to a two-rod ball joint in such a way that the new member possesses at least one degree of freedom makes the design considerably more complicated. The earliest multilink joint design appears to be that used in variable geometry truss (VGT) structures [5]. A VGT structure is a statically determinate truss with tetrahedral, octahedral or other simple geometric unit cells. The truss structure’s shape can be varied by changing the length of some of the struts. Two of the trusses in the VGT structure’s joint are directly hinged to a main hub while four others are hinged to two pivots which can rotate with respect to the hub [6]. Such a joint is an example of an open chain mechanism [7]. The truss rotation angle is limited by the physical interference between truss members at the joint. The trusses connections are usually offset at the joint and do not therefore intersect at a single point, making analysis of the joint quite complicated. A few other approaches for multi-truss rotational connection have been proposed. Stewart platform type mechanisms 1278 Figure 3. A pivot pin passing through the center of two concentric spherical shells enables free rotation of the two shells about the pin. The outer radius of the inner shell is assumed equal to the inner radius of the outer shell. utilize a different multi-truss articulating joint [8]. In this approach six links are joined together between a platform and a base using a parallel mechanism design. The joint has a significant offset because the links are connected using a series of hinges. Scissors mechanisms have been exploited by Hamlin and Sanderson [9] to connect three trusses. The links in their concentric joint intersect at a point so there is no offset, but the joint is difficult to fabricate. Bosscher and Ebbert-Uphoff [10] suggested two spherical joint mechanisms to implement multiple co-located spherical joints. Their ‘scalable’ design is an improvement over Hamlin’s mechanism in that it reduces the number of intermediate links, but the design then loses strength and becomes impractical for many applications. Song et al [11] proposed a spherical node that is capable of connecting three or more trusses. In this approach each truss passes through a hole in an outer spherical shell and is joined to an inner sphere. However, the joint only offers a very small range of rotations for the trusses because of the small clearance of the truss members inside the holes. Here we introduce a compact joint design suitable for constructing shape morphing or deployable truss structures. It allows the connection of up to six truss structures (or more generally any six rigid bodies (linkages)) using low rotation resistance pivots. This hexa-pivotal (H-P) joint has been fabricated at the millimeter size scale and appears to offer adequate strength for structural morphing applications over a wide range of size scales. Interrelationships between the rotational angles of the joint mechanism to determine unknown angles between the joint links are derived. Examples are provided to illustrate the application of the analysis. 2. Hexa-pivotal joint design Consider the rotation of two concentric spheres with respect to each other about a pivot pin that connects two spheres by penetration through their common center, figure 3. The pin itself is free to rotate about its axis. A hexa-pivotal joint consists of spherical shell elements (here called links) which can similarly rotate with respect to each other without interference. Figure 4(a) illustrates a pair of overlapped links cut from a pair of spherical shells and connected by a pivot pin that permits rotation of the links about the pin axis. The pivot pin passes through the common center of curvature of the two A rotational joint for shape morphing space truss structures Figure 5. A hexa-pivotal joint with 12 truss members (T 1–T 12) attached. In practice the trusses can be rigidly fixed to the links by mechanical fasteners or by welding. 3. Kinematic analysis Figure 4. (a) Two concentric spherical links can be cut from spherical shells. Both links can freely rotate about the common pivot pin though the axial movement of the links is restricted (via mechanical retainers). (b) A hexa-pivotal joint consisting of six spherical links ( L 1 − L 6 ) held in position using six pivoting pins ( P1 − P6 ). Two trusses (not shown) can be attached to each link. The joint is shown with all the pivot pins lying in a common plane. links. To ensure that 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. The spherical shell links are free to rotate about the pin but are restricted from moving axially along the pin by axial retainers (e.g. a cotter or ring and grooved pin). A spatial closed chain mechanism (the links form a closed loop) can be formed by sequentially connecting six spherical shell links, figure 4(b). This closed mechanism is referred to as a hexa-pivotal joint. Although a closed chain H-P joint is considered here, the joint can be used as an open chain mechanism by disengaging any of the pivots or by using a similar mechanism with fewer than six links. An open chain joint has more total degrees of freedom but loses strength. Although a joint can conceptually consist of two or more spherical links, here we are interested in a joint with six links: three inner and three outer links with a common radius of curvature at their contacting surfaces. The H-P joint can be used to connect 12 truss members, labeled T 1–T 12, figure 5. The trusses can be fixed to the spherical shell links by either mechanical attachment or by welding. The pivot pins can also be used as truss members although they must be permitted to freely rotate about their longitudinal axis. A closed chain hexa-pivotal joint is a constrained mechanism in which six links are connected by six revolute joints (pivots). Moving any link in the mechanism, as during shape morphing, can cause the other links to be reconfigured. The new shape of the closed chain H-P joint can be uniquely defined from the rotation angles of adjacent pairs of links about the common revolute joint of each pair. Therefore, in the shape morphing applications using the H-P joint, the shape of the structure can be controlled by actuators which control the rotation angle between the adjacent links. The number of actuators acting on a single H-P joint must be equal to the total degrees of freedom of the H-P joint. Although there are six angular rotations between the adjacent spherical linkages (because there is a total of six pivots in the H-P joint), the number of degrees of freedom of the closed chain mechanism needs to be determined. For a general spherical linkage in which each of the links is constrained to rotate about the same fixed point in space, the mobility, F , is given by the number of links and revolute joints [7]: F = 3(n − 1) − 2 p, (2) where n is the number of links and p is the number of revolute joints. For the H-P joint, n = 6 and p = 6, so the total degrees of freedom of the assembly is three. Therefore, controlling three (out of six) rotation angles of the adjacent spherical links can uniquely determine the H-P joint shape. The three unknown rotation angles of the H-P joint need to be found to fully determine the joint shape. The six spherical links in H-P joint are labeled L 1 , L 2 , . . . , L 6 , figure 4(b). An adjacent pair of links, e.g. L i−1 and L i , are hinged by a pivot pin, Pi . A flat joint shape, figure 4(b), results when the axis of all six pivot pins lie in the plane. The relative rotation angle of a pair of adjacent links, L i−1 and L i , about their common revolute joint, Pi , is denoted θi (note that L 6 precedes L 1 in the closed chain and the angle is denoted θ1 ; see figure 6). This angular rotation is 1279 A Y N Sofla et al intersect ensuring that the D–H parameters ai and si are zero: ai = 0, si = 0 for i = 1, 2, . . . , 6. (3) In addition, the in-plane (in the flat shape plane) angles between any pair of adjacent pivot pins, αi , are always 60◦ . The interrelationships of the six rotation angles play an important role in using the H-P joint for the design of shape morphing or adapting structures. The interrelationships of the angles at six pivots and, consequently, the joint shape can be determined when one or more of the angles are changed using the D–H approach [12]. Using the D–H notation [12], the [4 × 1] vector of coordinates is defined as v = [x, y, z, 1]T . (4) The [4 × 4] transformation matrix between Wi−1 and Wi is ⎡ Figure 6. The pivot rotation angle, θ1 , refers to the relative rotation of two adjacent links, L 6 and L 1 , about their common pivot pin, P1 , with respect to the flat shape. All pivot pin axes initially lay in a plane (shown by the hexagon) in the flat shape. cos θi ⎢ sin θi Ai = ⎣ 0 0 − sin θi cos αi cos θi cos αi sin αi 0 sin θi sin αi − cos θi sin αi cos αi 0 ⎤ ai cos θi ai sin θi ⎥ ⎦ si 1 (5) such that, represented with respect to the flat shape where all the rotation angles are defined to be zero. Figure 6 shows an example of a reconfigured H-P joint. The rotation angle, θ1 , results from rotation of links L 6 and L 1 about pivot P1 from the flat shape (the hexagon in figure 6). The joint mechanism of figure 6 is the same as the one in figure 4(b). For clarity, the truss members are not shown in figure 6. However, two holes can be seen in each spherical linkage that can be used to connect truss members to each link. Denavit and Hartenberg have suggested a notation for systematically representing a chained mechanism (by sequentially labeling and assigning a coordinate system to the links) in order to relate their kinematic motions [12]. The system of coordinates Wi (xi , yi , z i ) attached to link L i is illustrated in figure 7(a), in the original notation proposed by Denavit and Hartenberg. For the system of coordinates, Wi (xi , yi , z i ) in figure 7(a), z i is the direction along the axis of a revolute joint, xi lies along the common normal from z i−1 to z i and axis yi completes the right-handed coordinate frame. The geometric relationship between a pair of successive systems of coordinates, Wi−1 and Wi , is defined by using general Denavit– Hartenberg (D–H) parameters (ai , si , αi , θi ) [12], where ai is the distance between the origin of Wi and Wi−1 measured along xi ; si is the distance between xi−1 and xi measured along z i−1 ; αi is the angle between z i−1 and z i , measured in a righthand sense about xi ; and θi is the angle between xi−1 and xi measured in a right-hand sense about z i−1 ; see figure 7(a). The general D–H notation, figure 7(a), is applied to an HP joint in figure 7(b). The axis z i−1 is selected to be the axis of pivot Pi , which allows rotation at the pivot Pi be identified as θi . The rotation angle of links L 1 and L 6 about the axis of pivot P1 is θ1 , figure 7(b) (recall that the axis identified as z 6 precedes the axis z 1 in the closed chain). The H-P joint is designed so that all pivot pins always pass through the center of curvature of the links. Because all the links are concentric, the axes of pivot pins, z 1 to z 6 , always 1280 v i−1 = Ai v i . (6) The D–H parameters for the H-P joint are ai = 0, si = 0 αi = 60◦ . and The transformation matrix for the H-P joint then becomes ⎡ cos θi ⎢ sin θi Ai = ⎢ ⎣ 0 0 − 12 sin θi 1 2 √ 1 2 3 sin θi 2√ − 23 cos θi √ 3 2 0 0 cos θi 0 ⎤ 0⎥ ⎥. ⎦ 0 1 (7) Because all the fourth row and column’s elements, except for the element (4, 4) which is 1, have become zero the analysis can be simplified by defining a new equivalent [3 × 3] transformation matrix, Bi : √ ⎡ ⎤ 3 cos θi − 12 sin θi sin θi 2√ ⎢ ⎥ 1 Bi = ⎣ sin θi (8) cos θi − 23 cos θi ⎦ . 2 0 1 2 √ 3 2 The new vector of coordinates, u , and the transformation rule, equation (10), are then written as u = [x, y, z]T (9) u i−1 = Bi u i . (10) The transformation rule, equation (10), can be used to relate the coordinate of the neighboring links such that u 1 = B2 u 2 , u 2 = B3 u 3 , . . . , u 6 = B7 u 7 . (11) A closed chain mechanism requires the last link in the chain to be the same as the first one; therefore B7 = B1 and u 7 = u 1 . By using equation (11) we will have u 1 = B2 B3 B4 B5 B6 B1 u 1 . (12) A rotational joint for shape morphing space truss structures Figure 7. (a) The Denavit–Hartenberg (D–H) notation is used to label and assign coordinates to chain mechanisms [12]. (b) The D–H coordinates and parameters corresponding to the H-P joint cross section. Figure 8. Rotation of the linkages for (a) the 123-configuration with (0, 0, γ ), (b) the 123-configuration with (0, β, 0), and (c) the 134 configuration with (0, 0, γ ). Taking the symmetry of the chain into account and by using equation (12), 1 0 0 B1 B2 B3 B4 B5 B6 = 0 1 0 . (13) 0 0 1 The dependent system of equation (13) defines the interrelationship between the H-P joint parameters and can be used to determine the three unknown rotation angles. The examples later in the paper further clarify this method. Although the total number of degrees of freedom of the joint is three, several configurations are possible for a joint having three known (input) angles. For instance, an H-P joint with three known pivot angles (α, β, γ ) is called a 123configuration if (θ1 = α , θ2 = β and θ3 = γ ) while a joint with three known angles (α, β, γ ) is referred to as a 234-configuration joint if (θ2 = α , θ3 = β and θ4 = γ ). The second joint is identical to the first but rotated 60◦ about the x axis (the x axis in figure 7(b) is perpendicular to the paper). However, a joint in which two of three known angles (α, β, γ ) are non-adjacent (e.g. a 124-configuration, (θ1 = α , θ2 = β and θ4 = γ )) has different shape from a 123configuration with the same known angles. Expectedly, a joint with three known angles (α, β, γ ) with no known adjacent angles, such as the 135-configuration (θ1 = α , θ3 = β and θ5 = γ ), is totally different from the 123-configuration or 124configuration with the same known angles. This leads to three families of configurations for any set of three known angles (α, β, γ ), as summarized in table 1. As shown in table 1, 20 unique arrangements of pivots may accept a set of three known rotation angles (α, β, γ ). The shape and orientation of the H-P joint, therefore, can be identified by three known rotation angles and the corresponding pivots (123, 124, . . ., etc) amongst the 20 possible arrangements represented in table 1. The following examples illustrate application of the analysis in order to determine the shape (configuration) of the joint when the rotation angles of three of six pivots are known as input. Example 1. The rotation of two pairs of links about their common pivots is restricted while a motor controls the rotation angle of a third pair in a closed chain H-P joint. The output rotation angle of the motor is set at 30◦ ; therefore, the three known angles are (0, 0, 30), which means α = 0◦ , β = 0◦ , γ = 30◦ . 1281 A Y N Sofla et al Figure 10. Three symmetric arrangement of a hexa-pivotal joint. A flat shape with all the pins in a plane (a), hinge arrangement where two pins rotate relative to two others (b) and tripod shape where odd-number pivots have equal but different angle than the even-number pivots. Table 1. Three families of configurations with known pivot rotation angles (α, β, γ ). Any three-digit number represents those pivots with the known rotation angles. For example, 123 means θ1 = α , θ2 = β and θ3 = γ while 124 corresponds to θ1 = α , θ2 = β and θ4 = γ . Description of the family Figure 9. Unknown pivot rotation for (a) the 123-configuration, with fixed θ1 = θ2 = 30◦ and variable θ3 , (b) the 124-configuration with θ1 = θ2 = 30◦ versus θ4 and (c) the 135-configuration with fixed θ1 = θ3 = 30◦ and variable θ5 . If these known angles belong to the pivots # 1, #2, and #3 (123configuration) then we have θ 1 = 0◦ , θ 2 = 0◦ , θ3 = 30◦ . (14) By substituting (14) into the system of equation (13), the unknown rotation angles of pivots in the joint are found to be θ4 = 0◦ , θ5 = 0◦ , θ6 = 30◦ . The motion of this joint is simulated in figure 8(a), where two of the rotation angles are set to zero and a motor rotates its adjacent links with respect to each other. Zero angle for a pivot means that the relative rotation of the two adjacent links connected by the pin 1282 Family-1: the three pivots with known angles are neighbors Family-2: only two of the pivots with known angles are neighbors Family-3: none of the pivots with known angles are neighbors Configuration of the input angles of the joint Number of possible configurations in the family 123, 234, 345, 456, 561, 612 6 124, 125, 235, 236, 346, 341, 451, 452, 562, 563, 613, 614 135, 246 12 2 The total number of 20 possible pivot arrangement for a set of three known rotation angles (α, β, γ ) is restricted such that the pin and two neighboring pins always lie in a plane. Figure 8(b) illustrates motion of the joint for A rotational joint for shape morphing space truss structures Figure 11. (a) The range of rotation is limited by geometrical interference. In this design the interference of the external spherical linkage and the connected truss member of the adjacent linkage identifies the limiting rotation. (b) A spherical linkage design. a 123-configuration with (0, β, 0). In this figure the motor operates on the middle of three consecutive pivots. Figure 8(c) shows a 134-configuration with angles (0, 0, γ ), a family-2 configuration. Example 2. To illustrate the effect of the H-P joint family type on the joint shape, consider three H-P joints with 123-configuration, 124-configuration and 135-configuration in which the rotation angles at two pivots are known and a motor operates at a third pivot to change the rotation angle of the links, which are connected by the third pivot. For the H-P joint with 123-configuration, the rotation angle at pivot P1 is assumed to be fixed at 30◦ and the rotation angle at pivot P2 at 30◦ while the rotation angle of links at pivot P3 can vary between 0 and 90◦ (known). This joint is therefore referred to as a 123-configuration with known angles, (30◦ , 30◦ , γ ). To determine the joint shape, three unknown angles (θ4 , θ5 and θ6 ) are found by solving equation (13). The angles (θ4 , θ5 and θ6 ) are plotted in figure 9(a) as a function of rotation angle at pivot P3 , θ3 . Now, consider a 124-configuration joint with θ1 = 30◦ and θ2 = 30◦ (similar to the first joint), while for this case the rotation angle at pivot P4 varies between 0 and 90◦ . Figure 9(b) plots θ3 , θ5 and θ6 as a function of θ4 when θ1 = θ2 = 30◦ . Finally, for a 135-configuration joint with θ1 = θ 3 = 30◦ and variable θ5 , unknown rotation angles θ2 , θ4 and θ6 are plotted in figure 9(c). 4. Experimental implementation A prototype H-P joint is fabricated by connecting stainless steel links by tubular pivots, figure 10. The links are made by machining. Three interesting arrangements of the joint are demonstrated using the prototype in figure 10. In the flat shape, figure 10(a), all pivots lie in a plane whereas in the hinge configuration, figure 10(b), two of the pins (three corresponding linkages) are hinged with respect to two pins (the other three linkages) about the remaining aligned pins. Examples for a hinge arrangement are example 1 and figure 8(a). Figure 10(c) shows another symmetric arrangement called the tripod shape, where all odd-number pivots have same rotation angle but different than the evennumber ones. As an example, for a 135 arrangement with input angles (30◦ , 30◦ , 30◦ ), the other three angles are determined by means of figure 9(c) as θ2 = θ4 = θ6 = −7.5◦ . Rotation at each pivot is ultimately restricted by interference of the joint parts. For example, for the design in this paper which carries two truss members at each linkage in addition to the extended pivot pins, the interference happens between an external spherical linkage and the truss member of the adjacent link, figure 11(a). The limiting rotation angle θL can be calculated using the geometrical relationship, equation (15), for the design shown in the figure 11(b). sin(m) sin(n) −1 θL = sin + sin−1 √ (h/a)2 + sin2 (n) (h/a)2 + sin2 (m) √ (15) ( π6 h2, rt ) a ( π6 rp +d ). a − m= − and n = − As where a = illustrated in figure 10(b), rt is the radius of the truss member, rp the radius of the pivot pin, d is the distance of the hole from edge of the linkage, R the internal radius of external spherical linkage and h is half of the vertical distance between the truss connection center holes in the linkage. R2 5. Conclusion Deployable and shape morphing 3D truss structures require efficient joint designs which offer adequate degrees of freedom and are easily manufactured. The hexa-pivotal joint mechanism consists of six spherical linkages connected by six pivots to form a closed chain mechanism. The spherical linkages are designed to freely rotate about the common pivot. The outer surface of internal linkages contacts the internal surface of the neighboring outer linkages at common pivots without rotational interference, providing a design for strength and accuracy. The joint mechanism has a total of three degrees of freedom leading to interrelationship of the six rotation angles at the pivots. By knowing three of the angles as input, the other three rotation angles are determined. Twenty 1283 A Y N Sofla et al different arrangements for the joint mechanism are possible for any set of three known angles, making the joint capable of having several different shapes. The hexa-pivotal joint is easy to manufacture and can be fabricated to the desired size and strength. Having no offset between the links is another advantage of the joint which makes it easily programmable for precise positioning applications. 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