Optimal design of a three tape-spring hinge deployable space structure using an experimentally validated physics-based model

An optimal design approach is developed for a self-driven, self-locking tape-spring under a pure bending load in deployable space structures. A novel hinge with three tape springs is investigated and designed via an optimization process. Firstly, we investigate the steady-state moment and maximum stress of the hinge during deploying and folding processes using physics-based simulations. Experimental analyses are then conducted to verify the physics-based simulation results. Secondly, a parametric analysis is carried out to prove that both the tape spring thickness and subtended angle have significant effect on steady-state moment. A Response Surface Methodology (RSM) is employed to define an optimal surrogate model aimed at maximizing the steady-state moment, subjected to allowable stress. Finally, the Large Scale Generalized Reduced Gradient (LSGRG) optimization algorithm is used to solve the optimal design problem. Optimization results show that steady-state moment is increased by 19.5% while satisfying a maximum stress constraint. The proposed method is promising for designing novel deployable structures with high stability and reliability.