Journal Pre-proof
Folding kinematics of kirigami-inspired space structures
Antonio Pedivellano, Sergio Pellegrino
PII:
S0020-7683(24)00224-5
DOI:
https://doi.org/10.1016/j.ijsolstr.2024.112865
Reference:
SAS 112865
To appear in:
International Journal of Solids and Structures
Received date : 7 August 2023
Revised date :
10 April 2024
Accepted date : 2 May 2024
Please cite this article as: A. Pedivellano and S. Pellegrino, Folding kinematics of kirigami-inspired
space structures.
International Journal of Solids and Structures
(2024), doi:
https://doi.org/10.1016/j.ijsolstr.2024.112865.
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Journal Pre-proof
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Folding Kinematics of Kirigami-Inspired Space
1
Structures
2
Antonio Pedivellano
a,1
, Sergio Pellegrino
a,
∗
3
a
Graduate Aerospace Laboratories, California Institute of Technology, 1200 E California
Blvd, Pasadena, 91125, CA, USA
Abstract
4
This paper studies the folding of square, kirigami-inspired space structures
5
consisting of concentrically arranged modular elements formed by thin shells.
6
Localized elastic folds are introduced in the thin shells and different folding
7
strategies can be obtained by varying the location of the folds and the se-
8
quence of imposed rotations. Modeling each modular element with rigid
9
rods connected by revolute joints, numerical simulations of the kinematics
10
of folding are obtained, including constraints that represent folding aids and
11
a gravity offload system. These simulations are used to study two specific
12
packaging schemes, and the folding envelopes of a specific structure are an-
13
alyzed to identify the scheme that is easier to implement in practice. This
14
particular scheme is demonstrated by means of a physical prototype.
15
Keywords:
Deployable structures, Thin shells, Packaging, Kinematic
16
analysis, Loop closure, Origami
17
1. Introduction
18
Origami, the japanese art of paper folding, and kirigami, the variant of
19
origami that allows cuts as well as folds in the paper, have inspired novel
20
∗
Corresponding author
Email address:
sergiop@caltech.edu
(Sergio Pellegrino)
1
Current address: DCubeD, Burgweg 6, 82110 Germering, Germany
Preprint submitted to International Journal of Solids and Structures
May 14, 2024
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deployable space structures that can be efficiently packaged for launch and
21
built at low cost. Miura-ori (
Miura
,
1969
;
Miura and Pellegrino
,
2020
), a
22
well-known example of an origami-based modular packaging concept, has
23
led to the development of a novel deployable solar array (
Miura and Natori
,
24
1985
). Other examples include packaging schemes for thin films in solar
25
sails (
Guest and Pellegrino
,
1992
;
Furuya et al.
,
2011
) and flexible panels in
26
solar arrays (
Zirbel et al.
,
2013
) based on the concept of coiling a circular
27
membrane around a central hub. Removal of localized buckles near the folds
28
of a coiled membrane was achieved by allowing slip to occur along the folds
29
(
Arya et al.
,
2017
).
30
These concepts have been extended to large deployable structures that
31
will enable new space missions. An ongoing development is the ultralight,
32
scalable structural architecture for the Caltech Space Solar Power Project
33
(SSPP) (
Arya et al.
,
2016
), to provide square, flat structures that are tens
34
of meters in size and can be tightly folded into a cylindrical envelope. A
35
recent study (
Brophy et al.
,
2022
) has proposed a novel mission architecture
36
to reach Uranus and Neptune using very large ultralight solar arrays that
37
make it viable to use electric propulsion at great distances from the sun.
38
Large scale applications of this kind pose challenges beyond the existing
39
origami research. Hence, the specific challenges that are addressed in the
40
present study are related to the practical implementation of these folding
41
schemes, achievable with only simple folding aids. In particular, it has to be
42
ensured that no damage occurs during folding and that the self-weight of the
43
structure is properly supported at all stages of folding.
44
The specific focus of the present paper is the Caltech SSPP structure
45
2
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schematically shown in
Fig. 1a
. It consists of bending-stiff trapezoidal mod-
46
ular elements, also denoted as “strips”, in a four-fold symmetric arrangement
47
of concentric square loops. The strips are attached to four diagonal cords
48
stretched between a central deployment mechanism and the tips of four de-
49
ployable booms. The main structural elements of the trapezoids are thin-shell
50
longerons placed along the longitudinal edges of the trapezoids, connected
51
by transverse battens. Functional membranes, e.g., photovoltaic films and/or
52
RF radiating elements, are attached to the strips. Localized elastic folds in
53
the longerons allow compact packaging of these structures.
54
The packaging concept involves two steps, which are shown in
Fig. 1b
.
55
The first is a folding step, in which each quadrant of the structure is z-folded
56
to reach a star configuration. This step is followed by a coiling step in which
57
the four arms of the star are coiled into a cylindrical configuration. Note
58
that the folding step in
Fig. 1b
is different from
Arya et al.
(
2016
), as this
59
initial study had demonstrated the packaging concept with only thin films,
60
without considering relatively stiff structural elements.
61
The present paper studies the folding step through general numerical
62
simulations, with the objective of considering practically important effects,
63
such as the choice of constraints that provide support against self-weight,
64
and using easily implementable folding aids. Folding is very important to
65
the maturation of the overall structural concept, particularly because the
66
scope for exploring different folding strategies experimentally is limited by
67
the extensive use of carbon-fiber reinforced composite materials, whose brittle
68
behavior restricts the trial and error exploration feasible on physical models.
69
High-fidelity simulations, along the lines of
Pedivellano and Pellegrino
70
3
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(a) Architecture
(b) Packaging scheme
Figure 1: Structural architecture and packaging concept, with the folding step highlighted.
(
2022
), might be thought as ideal for such studies. However, high-fidelity
71
simulations are very time consuming and are best suited to the detailed
72
analysis of specific folding problems.
73
Reduced-order finite element models offer a computationally efficient al-
74
ternative to study elastic origami. A widely used approach is the bar-and-
75
hinge method, which models a planar structure as an assembly of elastic bar
76
elements forming a triangular pattern and revolute joints. Rotational springs
77
along the bars model the behavior of the creases and fold lines (
Filipov et al.
,
78
2017
;
Liu and Paulino
,
2017
). These models do a very good job in capturing
79
4
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the experimentally characterized behavior of deployable structures inspired
80
by Miura-ori, including snap-through behavior.
81
Several authors have applied this method to the hypar, the origami pat-
82
tern that is closest to the kirigami folding scheme studied in this paper.
83
Filipov and Redoutey
(
2018
) investigated the bi-stable behavior of the struc-
84
ture and showed that local and global buckling effects can be captured using
85
this analytical method.
Liu et al.
(
2019
) focused on the geometric properties
86
of the hypar and the tessellation of multiple hypar units to achieve multista-
87
bility. The main weakness of the bar-and-hinge method is that, because it
88
is based on an implicit finite element formulation, it struggles to deal with
89
singularities in the tangent stiffness matrix, e.g. at bifurcation points.
Liu
90
et al.
(
2023
) proposed an approach based on group theory to decompose the
91
global formulation of a hexagonal hypar into a series of independent problems
92
within different symmetry subgroups. This approach captured three differ-
93
ent bifurcation branches of the equilibrium path during folding of the hypar,
94
and examined the sensitivity of the corresponding peak loads to changes in
95
the distance between the creases. In general, the bar-and-hinge method is
96
not best suited to studying the motion of structures with a large number
97
of kinematic paths. The complexity of this problem has been recognized in
98
the physics literature, in which undesired kinematic paths are described as
99
distractors (
Stern et al.
,
2017
).
100
The simulation approach adopted in the present study is focused on the
101
specific structures of interest, which consists of long and narrow strips with
102
localized elastic folds at specific, fixed locations, as shown in the box in
103
Fig. 1b
. The elastic folds and the strip-to-cord connections are modeled as
104
5
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hinges (revolute joints) and the remaining parts of the strips are modeled
105
as rigid rods, hence modeling a complete structure as a mechanical link-
106
age. With this approach, established analytical techniques for structural
107
mechanisms can be used to develop an analytical framework to identify kine-
108
matically compatible paths for the structure. This formulation is then used
109
to study different folding procedures, defined by the location of the imposed
110
elastic folds and the order in which the square loops are folded.
111
The paper is organized as follows.
Section 2
introduces a kinematic model
112
of the structure where each strip is modeled as a linkage of rigid rods and
113
revolute joints. Then, the whole structure is modeled by multiple closed
114
loops, whose kinematics are simulated with a predictor-corrector algorithm.
115
Section 3
studies the kinematics of a single square loop.
Section 4
extends
116
the single-loop solution to structures consisting of multiple, interconnected
117
square loops.
Section 5
presents an experimental demonstration of the best
118
packaging scheme identified in the kinematic study. Finally,
Section 6
dis-
119
cusses the results and concludes the paper.
120
2. Kinematic Model and Simulations
121
Consider a linkage consisting of straight rigid rods connected by revolute
122
joints. A local reference frame is assigned to link
i
, see
Fig. 2
, with the origin
123
O
i
,x
i
,y
i
,z
i
at one end, the
z
i
-axis aligned with the axis of the hinge, the
124
x
i
-axis in the plane defined by the
z
i
-axis and the axis of the link, and the
125
y
i
-axis chosen such as to form a right-handed reference frame.
126
Using the
Denavit and Hartenberg
(
1955
) notation, the reference frame
127
6
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for the next link,
i
+ 1, is related to the frame for link
i
by:
128
O
i
=
T
i
O
i
+1
(1)
where the 3D coordinates of point
̃
O
i
are transformed to the 4
×
1 extended
129
form:
130
O
i
=
⎡
⎣
̃
O
i
1
⎤
⎦
(2)
Also,
131
T
i
=
⎡
⎣
R
i
v
i
0
1
×
3
1
⎤
⎦
(3)
where
R
i
,v
i
are respectively a rotation matrix and a translation vector.
132
(a) Translation
v
i
of
x
i
y
i
z
i
to the origin of
x
i
+1
y
i
+1
z
i
+1
(b) Rotation
φ
i
about
y
i
-axis, such that
z
i
lies in
y
i
−
z
i
+1
plane
(c) Rotation
ξ
i
about
x
i
to align
z
i
with
z
i
+1
(d) Rotation
β
i
about
z
i
to align
x
i
with
x
i
+1
Figure 2: Coordinate transformations between local reference frames on adjacent links
connected by a hinge.
7
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The rotation matrices are defined in terms of three Euler angles, obtained
133
from a sequence of elementary transformations that align the
i
-th reference
134
frame with the (
i
+ 1)-th frame. The following convention is used:
135
1. translation
v
i
of the coordinate system from
O
i
to
O
i
+1
(Fig.
2a
);
136
2. rotation about the
y
i
axis by
φ
i
, until the rotated
z
i
-axis is contained
137
in the
y
i
-
z
i
+1
plane (Fig.
2b
);
138
3. rotation about the new
x
i
axis by
ξ
i
, until the rotated
z
i
axis is aligned
139
with
z
i
+1
(Fig.
2c
);
140
4. rotation about the
z
i
=
z
i
+1
axis by
β
i
, until
x
i
is aligned with
x
i
+1
141
(Fig.
2d
).
142
With this convention,
φ
i
is the angle between the (
i
+1)-th hinge axis and
143
the normal to the
i
-th link axis;
ξ
i
is the twisting angle between the ends of
144
the
i
-th link, and
β
i
is the fold angle, i.e., the rotation around the (
i
+ 1)-th
145
hinge axis.
146
Coordinate transformations between non-consecutive links can be ob-
147
tained by multiplying the transformation matrices of the links in between:
148
T
k
1
=
T
1
T
2
...T
k
−
1
(4)
For a closed-loop kinematic chain, the initial and final coordinate frames
149
must coincide, which is equivalent to the condition:
150
T
1
T
2
...T
n
−
1
T
n
=
I
4
×
4
(5)
This matrix equation provides the loop-closure constraint for a kinematic
151
chain with
n
links. Although
Eq. (5)
corresponds to sixteen scalar equations,
152
only six equations are linearly independent, and it is shown in
Gan and
153
8
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Pellegrino
(
2006
) that an independent set of equations can be obtained from
154
the six off-diagonal terms above the main diagonal.
155
Finding a kinematic path for the linkage requires finding a solution of
156
Eq. (5)
. However, analytical solutions of this system of trigonometric equa-
157
tions are possible only for linkages much simpler than those considered in
158
the present paper. Therefore,
Eq. (5)
was solved numerically, using the con-
159
tinuation algorithm proposed in
Gan and Pellegrino
(
2006
). This algorithm
160
traces the motion of linkages with one or more degrees of freedom and iden-
161
tifies potential path-switching configurations (also known as kinematic bifur-
162
cations (
Kumar and Pellegrino
,
2000
)) with a predictor-corrector algorithm
163
that carefully monitors the approach to bifurcation points.
164
The incremental solution of
Eq. (5)
is based on a two-step algorithm.
165
In the predictor step, the loop-closure equations are linearized to find kine-
166
matically admissible tangent motions and an increment of the solution is
167
computed; in the corrector step, the linear prediction is iteratively updated
168
until the error resulting from the linearization becomes smaller than a set
169
threshold. These steps are outlined next.
170
2.1. Predictor step
171
Let
C
i
be the current configuration of the linkage, defined by the
m
172
variables
x
1
,x
2
,...x
m
.
173
In the predictor step, the loop-closure equation,
Eq. (5)
, is linearized near
174
C
i
to obtain:
175
A
1
Δ
x
1
+
A
2
Δ
x
2
+
...
+
A
m
−
1
Δ
x
m
−
1
+
A
m
Δ
x
m
=0
4
×
4
(6)
9
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where each of the coefficients
A
j
is the 4
×
4 matrix:
176
A
j
=
T
1
,j
|
C
i
...T
n
(
x
i
)
+
...
+
T
1
(
x
i
)
... T
n,j
|
C
i
(7)
Here,
i
denotes the time increment and
j
∈
[0
,m
] refers to the components
177
of the state vector
x
. Partial derivatives of the transformation matrices have
178
been denoted as
T
i,j
=
∂T
i
/∂x
j
.
179
Eq. (6)
provides up to six linearly independent scalar equations which,
180
as previously discussed, are obtained from the six terms above the main
181
diagonal of the matrix equation:
182
⎡
⎢
⎢
⎢
⎢
⎢
⎢
⎢
⎢
⎢
⎢
⎢
⎢
⎣
A
(1
,
2)
1
A
(1
,
2)
2
...A
(1
,
2)
m
−
1
A
(1
,
2)
m
A
(1
,
3)
1
A
(1
,
3)
2
...A
(1
,
3)
m
−
1
A
(1
,
3)
m
A
(2
,
3)
1
A
(2
,
3)
2
...A
(2
,
3)
m
−
1
A
(2
,
3)
m
A
(1
,
4)
1
A
(1
,
4)
2
...A
(1
,
4)
m
−
1
A
(1
,
4)
m
A
(2
,
4)
1
A
(2
,
4)
2
...A
(2
,
4)
m
−
1
A
(2
,
4)
m
A
(3
,
4)
1
A
(4
,
4)
2
...A
(3
,
4)
m
−
1
A
(3
,
4)
m
⎤
⎥
⎥
⎥
⎥
⎥
⎥
⎥
⎥
⎥
⎥
⎥
⎥
⎦
⎡
⎢
⎢
⎢
⎢
⎢
⎢
⎢
⎢
⎢
⎣
Δ
x
1
Δ
x
2
.
.
.
Δ
x
m
−
1
Δ
x
m
⎤
⎥
⎥
⎥
⎥
⎥
⎥
⎥
⎥
⎥
⎦
=
⎡
⎢
⎢
⎢
⎢
⎢
⎢
⎢
⎢
⎢
⎢
⎢
⎢
⎣
0
0
0
0
0
0
⎤
⎥
⎥
⎥
⎥
⎥
⎥
⎥
⎥
⎥
⎥
⎥
⎥
⎦
(8)
This equation can be written in compact form as:
183
A
p
Δ
x
= 0
(9)
The matrix
A
p
is the Jacobian of the system and the subscript
p
stands for
184
predictor.
185
Non-trivial solutions of
Eq. (9)
belong to the null space of
A
p
, and can
186
be obtained from the Singular Value Decomposition (SVD) of this matrix
187
(
Pellegrino
,
1993
;
Golub and Van Loan
,
2013
). This decomposition computes
188
three matrices
U, V
, and
S
such that
189
A
p
=
USV
T
(10)
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where
U
and
V
are orthogonal matrices containing the left- and right-singular-
190
vectors, with
U
∈
IR
6
×
6
and
V
∈
IR
m
×
m
, whereas
S
isa6
×
m
matrix
191
containing the singular values.
192
For pin-jointed structures,
Pellegrino
(
1993
) has shown that the columns
193
of
V
, corresponding to the null singular values, constitute a basis for the
194
space of inextensional mechanisms of the structure. Analogously, in the
195
present case, the columns of
V
identify a basis for the space of infinitesimal
196
configuration changes that do not violate the loop-closure equation.
197
Denoting this basis with
̃
V
, the predicted configuration of the linkage is:
198
x
p
=
x
i
+
̃
Vα
(11)
where
α
is a vector of scaling parameters for the independent inextensional
199
mechanisms that define the amplitude of the increment.
200
Note that, in the case of multiple mechanisms, a specific kinematic path
201
is followed during the entire simulation. The predictor algorithm calculates,
202
at each iteration, the dot product between the old eigenvector and the new
203
eigenvectors and picks the increment closest to the path in the previous
204
iteration.
205
2.2. Corrector step
206
The above linearized prediction results in a small error in the loop-closure
207
equation, which therefore is no longer satisfied exactly. Hence, the error
208
matrix
E
is defined from:
209
T
1
(
x
p
)
T
2
(
x
p
)
...T
n
−
1
(
x
p
)
T
n
(
x
p
)=
I
4
×
4
+
E
(12)
Eq. (12)
is linearized following the same approach as in Section
2.1
.A
210
correction to the state vector is computed by defining the vector form of the
211
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error,
e
=[
E
(1
,
2)
,E
(1
,
3)
,E
(2
,
3)
,E
(1
,
4)
,E
(2
,
4)
,E
(3
,
4)]
T
, and then the
212
correction is obtained from
213
A
c
Δ
x
=
−
e
(13)
where the subscript
c
stands for
corrector.
214
A least squares solution of this equation can be computed with the SVD
215
of
A
c
(
Pellegrino
,
1993
;
Kumar and Pellegrino
,
2000
):
216
Δ
x
=
−
rank(S)
i
=1
u
T
i
·
e
s
ii
v
i
(14)
where
u
i
and
v
i
are the left- and right-singular vectors of
A
c
, respectively.
217
The configuration of the linkage is updated with the correction:
218
x
c
=
x
p
+Δ
x
(15)
and the correction step is repeated until the L2 norm of the error
E
(or any
219
other metric of choice) becomes lower than a chosen tolerance, set to 10
−
9
220
in the algorithm. In a typical simulation, the error converges within two
221
iterations of the correction step.
222
3. Folding a Loop of Four Strips
223
This section studies the folding kinematics of a square loop formed by
224
strips of length 2
L
along the mid-line and width 2
w
,
Fig. 3
. The strips are
225
connected at the ends by hinges aligned with the diagonals of the square.
226
According to the mobility formula for closed kinematic chains (
Uicker et al.
,
227
2003
;
McCarthy and Soh
,
2010
), a closed loop requires at least seven revolute
228
joints to have an internal degree of freedom. Therefore, at least three folds
229
are needed and, in fact, four is the minimum number if folding is required to
230
12
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preserve the symmetry of the structure. However, the folding of nested loops
231
requires at least two folds in each strip and hence this is the case considered
232
here.
233
The non-dimensional parameter
λ
defines the distance between the folds.
234
Note that
λ
= 0 corresponds to a single fold at the center of the strip, and
235
λ
= 1 corresponds to two folds at the ends. Since the folds are not allowed
236
to cross the diagonal battens, the admissible range is
λ
∈
[0
,λ
max
] with:
237
λ
max
=1
−
w
L
(16)
Figure 3: Geometry of square loop, with location of diagonal hinges and fold lines.
Figure 4
shows the model of the square loop. The joints have two ro-
238
tational degrees of freedom around perpendicular axes, as shown in more
239
detail in
Fig. 5
, and hence are equivalent to hinges with a variable direction
240
axis. Hence, both bending
β
and torsion
ξ
of a strip are allowed. Therefore,
241
the kinematic chain for the square loop contains
n
= 12 links with
m
=24
242
degrees of freedom.
243
13
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Figure 4: Kinematic chain of four strips forming a square loop.
Figure 5: Detail of the kinematic model for a strip, with relevant dimensions.
14
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A general strip
j
is shown in
Fig. 5
. The elementary transformations for
244
this three-link model include the parameters
β
ij
and
ξ
ij
, corresponding to
245
the degrees of freedom of the joints. The remaining (constant) parameters
246
correspond to the geometry of the link and are provided in
Table 1
.
247
The angle
φ
i
is defined in
Fig. 2b
. Due to the four-fold symmetry of
248
the structure, the rotation between the hinges and the folds is 45
◦
for all of
249
the strips (hinges and folds are defined in
Fig. 3
). The components of the
250
translation vector only depend on the position of the folds.
v
y
is always zero,
251
as the
y
i
-axis is perpendicular to the axis of the link, by construction. The
252
distances in the model are non-dimensionalized by the length 2
L
, so that the
253
obtained results are valid for strips of any size.
φ
i
v
x
v
y
v
z
T
1
j
π
4
1
−
λ
2
√
2
0
−
1
−
λ
2
√
2
T
2
j
0
λ
00
T
3
j
π
4
1
−
λ
2
00
Table 1: Denavit-Hartenberg parameters for the transformation matrices between adjacent
links of a strip.
254
Once the transformation matrices have been defined, the loop-closure
255
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equation can be written in the form:
256
4
j
=1
3
i
=1
T
ij
=
I
4
×
4
(17)
and can be solved as described in
Section 2
.
257
Any configuration of this system is defined the vector
x
∈
IR
24
×
1
:
258
x
=
β
11
β
21
β
31
β
12
... β
34
ξ
11
ξ
21
ξ
31
... ξ
34
T
(18)
In general, there are at least 24
−
6 = 18 degrees of freedom, assuming
259
that the Jacobian of
Eq. (8)
has full-rank. Solutions with specific symmetry
260
properties can be obtained by introducing additional constraints.
261
3.1. Four-Fold-Symmetric Folding
262
Given that a square loop has four-fold symmetry, folding schemes that
263
preserve this symmetry are of particular interest. This symmetry assumption
264
greatly reduces the number of independent variables, by setting
β
ij
=
β
i
1
and
265
ξ
ij
=
ξ
i
1
∀
j
∈
[1
,
4]. Symmetry also requires the folds on a strip to have the
266
same angle (
β
21
=
β
11
) and prevents any torsion between their axes (
ξ
21
= 0).
267
It should be noted, however, that torsion is allowed between the hinges and
268
the folds, under the constraint
ξ
31
=
−
ξ
11
. Therefore, only three independent
269
variables remain:
270
•
β
11
, denoted as the fold angle;
271
•
β
31
, denoted as the hinge angle;
272
•
ξ
11
, denoted as the torsion between the hinges and the folds.
273
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With these constraints, the loop-closure equation and its linearized ver-
274
sions in
Eq. (8)
,
Eq. (9)
,
Eq. (13)
, reduce to a system of 3 equations in 3
275
unknowns. The reduced Jacobian matrix,
̃
A
p
, has rank 2 throughout the
276
folding process, so that there is only one kinematically-admissible path be-
277
tween planar and folded configuration. Snapshots of the solution for four
278
different values of the hinge angle
β
31
are shown in
Fig. 6
.
279
(a) Hinge angle
β
31
=0
◦
(b) Hinge angle
β
31
=90
◦
(c) Hinge angle
β
31
= 135
◦
λL
(d) Hinge angle
β
31
= 180
◦
Figure 6: Four-fold symmetric folding of a loop of four strips.
Figure 7
shows the variation of the fold angle
β
11
and the strip torsion
ξ
11
280
with the hinge angle
β
31
. The plot shows that
β
11
monotonically decreases
281
from 0
◦
to -45
◦
when the hinge angle is increased from 0
◦
to 180
◦
. The torsion
282
of the strip
ξ
11
remains zero throughout the entire folding.
283
Figure 8
plots the variation of the singular values of
̃
A
p
as a function
284
of
β
31
. One of the singular values is always equal to zero, indicating that
285
there is a unique kinematic path. The other two singular values are greater
286
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Figure 7: Four-fold-symmetric kinematic solution for single square loop.
Figure 8: Singular values of
̃
A
p
along the four-fold-symmetric path. The two configurations
shown on the left correspond to two different kinematic paths at the bifurcation point.
18
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than zero for all values of
β
31
, except for the initial and final point (
β
31
=0
287
and
β
31
= 180
◦
), where the rank of
̃
A
p
drops to 1. This corresponds to a
288
bifurcation point, at the intersection of two different kinematic paths. In
289
the alternative folding path, the ends of the strips fold inwards, towards the
290
center of the square, see Mode II in
Fig. 8
. To avoid the bifurcation, a
291
small perturbation of 10
−
3
rad was applied to the initial configuration of the
292
kinematic simulation.
293
The results in
Fig. 7
were obtained for a fold spacing of
λ
=0
.
5, but the
294
results are identical for any other values of
λ
. This means that, although
295
different values of
λ
correspond to different geometries of the structure, the
296
relationship between the variables
β
11
,ξ
11
and
β
31
remains unchanged.
297
The four-fold symmetric path considered in this section provides a single
298
degree-of-freedom mechanism with torsion-free kinematics, which is beneficial
299
for the structural integrity of the space structure. Therefore, it will used as
300
the baseline for the packaging kinematics of a multi-square-loop structure in
301
Sec.
4
.
302
3.2. Folding with a Single Plane of Mirror Symmetry
303
The kinematic formulation presented in this paper can capture more gen-
304
eral kinematic paths, which will be demonstrated by studying an alternative
305
packaging strategy. A mirror symmetric folding scheme, in which a square
306
loop is folded in two steps by moving two corners at a time, is shown in
307
Fig.
9
.
308
One of the outermost strips is folded first, by imposing 180
◦
relative
309
rotations at the end hinges. The rest of the structure follows in a symmetric
310
fashion. Then, the opposite strip is folded in a similar way.
311
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Figure 9: Mirror symmetric folding sequence for a square loop: corners C1 and C2 are
folded first (strip 1), followed by corners (C3 and C4).
To model the kinematics of this folding scheme, the 24 variables in the
312
general model of the square loop, Eq.
18
are reduced to only 11 by setting
313
the following 13 symmetry conditions: for bending
β
21
=
β
11
,
β
23
=
β
13
,
314
β
33
=
β
32
,
β
14
=
β
22
,
β
24
=
β
12
,
β
34
=
β
11
, and for torsion
ξ
21
=0,
ξ
31
=
−
ξ
11
,
315
ξ
23
=0,
ξ
33
=
−
ξ
13
,
ξ
14
=
−
ξ
32
,
ξ
24
=
−
ξ
22
,
ξ
34
=
−
ξ
12
. Hence, the reduced
316
model includes only 11 degrees of freedom (6 bending rotations
β
j
and 5
317
torsional rotations
ξ
j
).
318
During the second folding step,
β
31
and
ξ
11
are set to zero to fix the folded
319
corners of the square loop.
320
Under these assumptions, the linearized kinematics in Eq.
8
becomes
321
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underdetermined, as it has 6 equations and 11 unknowns. Eq.
11
provides a
322
5-dimensional space of solutions.
323
While arbitrary values of
α
would be kinematically feasible, practically
324
useful solutions are obtained by solving the following optimization problem:
325
α
∗
= arg min
α
J
(19)
in which
J
=
3
i
=1
w
i
J
i
and the weights
w
i
were all set equal to one in this
326
particular case.
327
The cost function imposes the following practical requirements:
328
•
J
1
: planarity.
During folding, the structure remains in contact with
329
a planar surface, to offload gravity;
330
•
J
2
: displacement.
The largest displacements (rotations) should
331
correspond to the degrees of freedom being controlled;
332
•
J
3
: torsion.
Torsional rotations should be as small as possible, to
333
minimize the stress on the structure.
334
The condition
J
1
is defined as follows:
335
•
First, the coordinates of the lower longerons of the strip are evalu-
336
ated at the joint locations, and expressed in their local frames (
P
i
=
337
[0
,
0
,
−
w,
1]
T
at the elastic fold locations,
P
i
=[0
,
0
,
−
√
2
w,
1]
T
at the
338
location of the hinges between strips, where the notation of
Eq. (2)
has
339
been used.
340
•
The coordinates
P
i
are converted to the same reference using the com-
341
pound transformations
P
(0)
i
=
T
i
0
P
i
;
342
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•
A global frame is defined, with the origin at the centroid
O
of the
343
points
P
(0)
i
and the axes aligned with the 0-th local frame. The global
344
coordinates of the points were computed as
P
i
=
P
(0)
i
−
O
;
345
•
A plane passing through these points is defined, using the Princi-
346
pal Component Analysis (PCA) (
Jolliffe
,
2005
) on the matrix
X
=
347
[
P
1
,P
2
,...P
n
]. The matrix contains the coordinates of the above de-
348
fined points, 5 points on each longeron for a total of 20 points on the
349
4 longerons. The PCA returns the eigenvectors of the covariance ma-
350
trix
X
T
X
; the eigenvector corresponding to the smallest eigenvalue of
351
X
T
X
defines the normal
n
to the fitting plane.
352
•
Finally,
J
1
is defined as:
J
1
=
i
P
i
P
i
·
n
.
353
The condition
J
2
states that the displacement of the controlled D.o.F.’s
354
should be larger than any other component, and hence
355
J
2
=1
−
x
c
(20)
where
x
c
is a vector containing the components of
x
m
associated with the
356
control variables.
357
The condition
J
3
minimizes the torsional components and is stated as:
358
J
3
=
[
ξ
11
, ...ξ
34
]
(21)
The optimization problem was solved using a quasi-Newton algorithm in
359
MATLAB 2020, with the function
fminunc
.Fig.
10
shows the evolution of
360
the bending and torsional degrees of freedom for the 2-step mirror symmetric
361
folding path, on a strip with
λ
=0
.
5.
362
22
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In the first step, the control variable is
β
31
, which increases monotonically
363
from 0
◦
to 180
◦
, while the fold angle
β
11
on strip 1 decreases to approximately
364
−
90
◦
. The other bending angles vary by up to approximately 30
◦
. Torsion is
365
generally small, with the largest value corresponding to
ξ
22
, i.e. the twisting
366
between the fold angles associated with strips 2 and 4.
Figure 10: Two-step folding with a plane of symmetry.
367
These results show that it is possible to star-fold a square loop structure
368
by controlling two degrees of freedom. Note that different kinematic paths
369
controlled by two degrees of freedom are also possible.
370
4. Folding of Nested Square Loops
371
Section
3.1
has computed, for a single square loop, a four-fold-symmetric
372
folding path with a single-degree-of-freedom. When multiple square loops
373
are connected to form a nested space structure, the loops can be folded in
374
sequence by ensuring that the loop kinematics are compatible.
375
23