A rollable flexible solar cell array deployment and retraction mechanism and method

Abstract

The application discloses a winding type flexible solar cell array unwinding and winding mechanism and method, which comprises a top reel device, an unwinding and winding control device, a root beam device, a pressing and releasing device and a solar blanket device; the top reel device is located at the top of the unwinding and winding mechanism and provides support for unwinding and winding of the solar blanket device; the unwinding and winding control device is symmetrically distributed on both sides of the unwinding and winding mechanism; the root beam device provides a fixed position for carrying of the solar cell array and reserves a mechanical interface and an electrical interface; the pressing and releasing device is installed on a root yoke in the root beam device. The unwinding and winding mechanism improves the mass power ratio of the solar cell array through winding type configuration design, provides unwinding power through a bistable composite material support rod, and has the advantages of light weight and reliability, high winding ratio, repeatable unwinding and winding and modularity and easy expansion.

Description

Technical Field

[0001] This invention belongs to the field of solar energy technology, specifically relating to a winding flexible solar cell array deployment and recovery mechanism and method. Background Technology

[0002] Space solar arrays are the sole energy source for the vast majority of spacecraft operating in orbit. They convert solar energy into electrical energy and are a key component of a spacecraft's energy system, determining mission success and on-orbit operational lifespan. Currently, rigid and semi-rigid solar arrays are the most widely used forms in space applications, but their weight and volume increase rapidly in proportion to the power required by the spacecraft's payload, making them difficult to adapt to the expansion of future space engineering.

[0003] In recent years, low-Earth orbit satellite constellations, space-based solar power stations, and international lunar research stations have been proposed and implemented. The next generation of space solar arrays requires extremely high storage and power ratios, as well as controllable deployment and retraction capabilities. To address these issues, flexible solar array deployment mechanisms, such as scissor-type mechanisms and flexible truss-type extension mechanisms, have emerged. However, existing designs suffer from problems such as design complexity, difficulty in modular expansion, and difficulty in retraction after deployment. Summary of the Invention

[0004] To overcome the shortcomings of existing technologies, this invention provides a roll-up flexible solar array deployment and retraction mechanism and method, including a top roll-up device, a deployment and retraction control device, a root crossbeam device, a clamping and releasing device, and a solar blanket device. The top roll-up device is located at the top of the deployment and retraction mechanism, providing support for the deployment and retraction of the solar blanket device. The deployment and retraction control device is symmetrically distributed on both sides of the deployment and retraction mechanism. The root crossbeam device provides a fixed position for mounting the solar array and reserves mechanical and electrical interfaces. The clamping and releasing device is installed on the root yoke in the root crossbeam device. This invention's deployment and retraction mechanism improves the power-to-weight ratio of the solar array through a roll-up configuration design and provides deployment power through a bistable composite material support rod, offering advantages such as lightweight reliability, high retraction ratio, repeatable deployment and retraction, and modular expansion.

[0005] The technical solution adopted by this invention to solve its technical problem is as follows:

[0006] A roll-up flexible solar cell array deployment and retraction mechanism includes a top roll assembly, a deployment and retraction control assembly, a root crossbeam assembly, a clamping and releasing assembly, and a solar blanket assembly.

[0007] The top roll assembly, located at the top of the unfolding and retracting mechanism, includes a roll support, a clamping arm support, a roll tube, a mandrel, a mandrel bearing, and a bearing mounting base; the roll tube includes a blanket winding roll and a rod winding roll; the mandrel passes through the roll support and the mandrel bearing and extends through the roll tube; the top roll assembly provides support for the unfolding and retraction of the sun blanket device;

[0008] The deployment and retraction control device is symmetrically distributed on both sides of the deployment and retraction mechanism, including a bistable composite material support rod, a stabilizing rod, a radial clamping constraint mechanism, and a deployment and retraction speed control mechanism. The bistable composite material support rod is wound in the opposite direction on a winding reel, utilizing the strain energy stored in the winding reel itself to provide deployment power and providing rigid support after full deployment. One end of the radial clamping constraint mechanism is connected to a clamping arm support via an arm support connecting shaft, and the other end is connected to the stabilizing rod, constraining the radial natural expansion deformation of the reverse-wound bistable composite material support rod, allowing it to wind and achieve directional extension. The deployment and retraction speed control mechanism controls the deployment time of the battery array and enables the battery array to retract after deployment.

[0009] The root crossbeam device, located at the root of the deployment and retraction mechanism and connected to the spacecraft body, includes a motor mounting base, support rod pressure strip, tension spring, tension spring connecting frame, reel limiting component and root yoke, providing a fixed position for mounting the battery array and reserving mechanical and electrical interfaces;

[0010] The clamping release device is installed on the root yoke in the root crossbeam device and includes a binding rope, a hot knife module, and a hot knife module mounting base. When the battery array is stored, the binding rope passes through the wire groove of the hot knife module mounting base and binds the reel tube to the reel limiter of the root crossbeam device. When the battery array is unfolded, the resistor in the hot knife module is energized and heats up, melting the binding rope and unlocking the mechanism.

[0011] The sun blanket device is located inside a rectangular frame consisting of a top roll assembly, a bistable composite material support rod, and a root crossbeam assembly. It includes a force transmission beam, a flexible substrate, and cushioning foam. One end of the force transmission beam is connected to the root crossbeam assembly via a tension spring, and the other end is wound around the blanket roll in the top roll assembly.

[0012] One end of the roller bracket in the top roller device is connected to the spindle; the angle of the clamping arm bracket is variable, and one end is connected to the arm bracket connecting shaft; the other ends of both the roller bracket and the clamping arm bracket are connected to the stabilizing rod.

[0013] The radial clamping constraint mechanism includes an arm support connecting shaft, a spring clamping assembly, a pre-tightening assembly, and a stabilizer bar support; the spring clamping assembly includes a spring connector, a clamping roller, a roller limiting ring, roller male and female rivets, and a clamping spring; the spring connector, according to its configuration, includes a top spring connector, a middle spring male connector, a middle spring female connector, a bottom spring male connector, and a bottom spring female connector; the pre-tightening assembly includes a pre-tightening bracket, a pre-tightening bracket guide, a pre-tightening roller, a pre-tightening roller connecting shaft, a pre-tightening torsion spring, and a pre-tightening torsion spring connecting shaft;

[0014] The roller rivets pass through the spring connector, the clamping roller, and the roller limiting ring; the clamping spring is an Ω-shaped metal spring, which is connected to the front and rear spring connectors through the through hole reserved in the straight section. During the deployment and retraction of the battery array, the radial thickness of the bistable composite material support rod changes, and the arc section of the clamping spring deforms with the change in radial thickness, providing radial pressure to the bistable composite material support rod in the reverse winding state through the clamping roller;

[0015] The preload assembly is located at the bottom of the radial clamping constraint mechanism. One end is connected to the spring clamping assembly via the preload bracket guide, and the other end is connected to the stabilizer rod via the stabilizer rod bracket. The preload roller is connected to the preload bracket via the preload roller connecting shaft and is tangent to the inner side of the deformation transition zone of the bistable composite material support rod. The preload torsion spring connecting shaft connects the preload bracket and the stabilizer rod bracket. The preload torsion spring is located on the preload torsion spring connecting shaft, with one end embedded in the round hole of the preload bracket and the other end tangent to the stabilizer rod bracket, providing a certain preload force to the preload roller.

[0016] The speed control mechanism for extending and retracting includes a tether rope, a tether rope fixing ring, a speed control motor, and a rope wheel; the tether rope fixing ring is installed at both ends of the stabilizer bar, one end of the tether rope is connected to the tether rope fixing ring, and the other end is wound around the rope wheel; the speed control motor is installed on the motor mounting base of the root crossbeam device; the rope wheel is fixed to the output shaft of the speed control motor by a set screw;

[0017] The root yoke is equipped with a support rod adjusting seat, a support rod pressure strip, a tension spring connecting frame, a clamping release device, and a motor mounting seat from the outside to the inside. Multiple tension spring connecting frames are evenly distributed on the root yoke. Each tension spring connecting frame has multiple small holes machined at its front end. One end of a stainless steel tension spring passes through these small holes, and the other end passes through a metal clip on the force transmission beam and connects to the sun blanket device. The support rod pressure strip is installed in the middle of the fixed end of the bistable composite material support rod, with the width of the middle strip being greater than the widths of the two side strips. Screws pass through the pre-drilled through holes in the support rod pressure strip, fixing the bistable composite material support rod to the root yoke via the support rod adjusting seat.

[0018] Preferably, the surface of the winding reel is milled with a planar groove and drilled with holes to fix the extended end of the bistable composite material support rod.

[0019] Preferably, the bistable composite material support rod is configured as a C-shaped cross-section thin-walled slit tube, which is made by laying and curing multiple layers of ultra-thin fabric or unidirectional composite fiber-reinforced prepreg at a specific angle. It utilizes the elastic strain energy stored in its reverse-wound state to provide power for the deployment of the battery array without the need for an additional drive mechanism.

[0020] Preferably, the root yoke is made of rectangular cross-section aluminum profile or rectangular honeycomb sandwich panel.

[0021] Preferably, there are four tension spring connecting frames, evenly distributed on the root yoke, and four small holes are machined at the front end of the tension spring connecting frame.

[0022] Preferably, the force transmission beam consists of two aluminum strips, one above the other, with evenly distributed round holes on the surface of the aluminum strips. A metal clip passes through the round holes to fix the two aluminum strips, and a tension spring passing through the round holes applies the tension load evenly to the flexible substrate.

[0023] Preferably, the cushioning foam is in the form of long strips, made of high-temperature resistant polyimide material, and is attached at equal intervals to the back of the flexible substrate to provide shock absorption and cushioning effect.

[0024] A method for deploying and retracting a roll-up flexible solar cell array deployment and retraction mechanism, the specific steps of which are as follows:

[0025] Step 1: Once the flexible solar array reaches its designated location in space, the onboard computer or ground control station issues an unlocking command;

[0026] Step 2: Upon receiving the unlocking command, the electronic control system of the flexible solar cell array deployment and retraction mechanism is activated, the pressing and releasing device is activated, the hot knife module is energized to burn off the binding rope, and the reel tube is released.

[0027] Step 3: The onboard power supply supplies power to the speed control motor. The speed control motor starts to work and drives the rope wheel to rotate in the forward direction. The tethered traction stabilizer is released at a constant speed. The bistable composite material support rod moves in the specified direction by relying on its own elastic strain energy and the constraint of the radial compression constraint mechanism, which drives the solar blanket device to unfold synchronously. The tension spring applies a uniform tension load to the solar blanket device through the force transmission beam.

[0028] Step 4: After the sun blanket device is fully deployed, the speed control motor stops supplying power, and the structure is supported by two bistable composite material support rods.

[0029] Step 5: When retracting, the speed control motor is powered on again, causing the rope wheel to rotate in the opposite direction. The stabilizing rod is pulled back by the tether rope 22, and finally the flexible solar cell array is deployed and retracted.

[0030] The beneficial effects of this invention are as follows:

[0031] This invention provides a roll-up flexible solar array deployment and retraction mechanism. This mechanism improves the power-to-weight ratio of the solar array through its roll-up configuration design. Deployment power is provided by the strain energy stored in the reverse-winding of bistable composite material support rods, eliminating the need for an additional drive mechanism. Radial compression constraint during the deployment and retraction process is achieved through the adaptive deformation of elastic spring assemblies. Deployment speed control and slow retraction are achieved through a deployment and retraction speed control mechanism composed of tethers and motors. The solar array deployment and retraction mechanism of this invention exhibits good deployment rigidity and possesses comprehensive advantages such as lightweight reliability, high storage ratio, low complexity, repeatable deployment and retraction, and modular expansion. Attached Figure Description

[0032] Figure 1 This is a schematic diagram of the unfolded state of the roll-up flexible solar cell array unfolding and retracting mechanism of the present invention;

[0033] Figure 2 This is a schematic diagram of the coiled flexible solar cell array deployment and retraction mechanism of the present invention in its stored state.

[0034] Figure 3 This is a schematic diagram of the top scroll device of the present invention;

[0035] Figure 4 This is a schematic diagram of the radial clamping constraint mechanism of the present invention;

[0036] Figure 5 This is a schematic diagram of the root beam device and the sun blanket device of the present invention.

[0037] Explanation of reference numerals in the attached figures:

[0038] Ⅰ-Top reel device, Ⅱ-Unfolding and retracting control device, Ⅲ-Root crossbeam device, Ⅳ-Pressure release device, Ⅴ-Sun blanket device; 1-Reel bracket, 2-Pressure arm bracket, 3-Reel tube, 3-1-Wrapping reel, 3-2-Wrapping rod reel, 4-Core shaft, 5-Core shaft bearing, 6-Bearing mounting seat, 7-Bistable composite material support rod, 8-Stabilizing rod, 9-Arm bracket connecting shaft, 10-Spring connector, 10-1Top spring connector, 10-2Middle spring male connector, 10-3Middle spring female connector, 10-4Bottom spring male connector, 10-5Bottom spring female connector, 11-Pressure roller, 12- 13-Roller limiting ring, 14-Pressure spring, 15-Pre-tension bracket, 16-Pre-tension bracket guide, 17-Pre-tension roller, 18-Pre-tension roller connecting shaft, 19-Pre-tension torsion spring, 20-Pre-tension torsion spring connecting shaft, 21-Stabilizer bracket, 22-Tether, 23-Tether fixing ring, 24-Speed ​​control motor, 25-Rope wheel, 26-Motor mounting base, 27-Support rod pressure bar, 28-Support rod adjustment, 29-Tension spring, 30-Tension spring connecting bracket, 31-Root yoke, 32-Binding rope, 33-Hot knife module, 34-Hot knife module mounting base, 35-Force transmission beam, 36-Flexible substrate, 37-Buffer foam. Detailed Implementation

[0039] The present invention will be further described below with reference to the accompanying drawings and embodiments.

[0040] This invention provides a roll-up flexible solar cell array deployment and take-up mechanism. This mechanism improves the mass-to-power ratio of the cell array through a roll-up configuration design and provides deployment power through a bistable composite material support rod. It has advantages such as being lightweight and reliable, having a high storage ratio, being reusable, and being modular and easily expandable.

[0041] This invention provides a roll-up flexible solar cell array deployment and retraction mechanism, comprising:

[0042] The top reel device, located at the top of the unfolding mechanism, includes a reel support, a clamping arm support, a reel tube, a mandrel, a mandrel bearing, and a bearing mounting seat. The reel tube includes a blanket reel and a rod reel. The mandrel passes through the reel support and the mandrel bearing and extends through the reel tube.

[0043] The deployment and retraction control device, symmetrically distributed on both sides of the deployment and retraction mechanism, includes a bistable composite material support rod, a stabilizing rod, a radial clamping constraint mechanism, and a deployment and retraction speed control mechanism. The bistable composite material support rod is wound in the opposite direction on the winding reel, utilizing the strain energy stored in the structure itself to provide deployment power and providing rigid support after full deployment. One end of the radial clamping constraint mechanism is connected to the clamping arm support via an arm support connecting shaft, and the other end is connected to the stabilizing rod. It constrains the radial natural expansion deformation of the bistable composite material support rod after reverse winding, making it tightly wound and achieving directional extension. The deployment and retraction speed control mechanism controls the deployment time of the battery array and enables the battery array to retract slowly after deployment.

[0044] The root crossbeam device, located at the root of the deployment and retraction mechanism and connected to the spacecraft body, includes a motor mounting base, support rod pressure strip, tension spring, tension spring connecting frame, roll limit component and root yoke, providing a fixed position for mounting the flexible solar cell array and reserving mechanical and electrical interfaces;

[0045] The clamping and releasing device, installed on the root yoke in the root crossbeam assembly, includes a binding rope, a hot knife module, and a hot knife module mounting base. When the battery array is retracted, the binding rope passes through the wire groove of the hot knife module mounting base and binds the reel tube to the reel limiter of the root crossbeam assembly. When the battery array is deployed, the resistor in the hot knife module is energized and heats up, melting the binding rope and unlocking the mechanism.

[0046] The sun blanket device is located inside a rectangular frame consisting of a top roll assembly, bistable composite material support rods, and a root crossbeam assembly. It includes a force transmission beam, a flexible substrate, and cushioning foam. One end of the force transmission beam is connected to the root crossbeam assembly via a tension spring, and the other end is wound around the blanket winding roll in the top roll assembly.

[0047] One end of the reel bracket in the top reel assembly is connected to the mandrel, the angle of the clamping arm bracket is variable, and the other end is connected to the arm bracket connecting shaft. The other ends of both are connected to the stabilizing rod. A flat groove is milled and a hole is drilled on the surface of the reel to fix the extension end of the bistable composite material support rod.

[0048] The bistable composite material support rod in the deployment and retraction control device is a C-shaped cross-section thin-walled slit tube, which is made of multi-layer ultra-thin fabric or unidirectional composite fiber reinforced prepreg through specific angle lay-up and curing. The elastic strain energy stored in its reverse winding state can provide power for the deployment of the battery array without the need for an additional drive mechanism.

[0049] The radial clamping constraint mechanism in the extension and retraction control device includes an arm support connecting shaft, a spring clamping assembly, a pre-tightening assembly, and a stabilizer bar support. The spring clamping assembly includes a spring connector, a clamping roller, a roller limiting ring, roller male and female rivets, and a clamping spring. The spring connector, according to its configuration, includes a top spring connector, a middle spring male connector, a middle spring female connector, a bottom spring male connector, and a bottom spring female connector. The pre-tightening assembly includes a pre-tightening bracket, a pre-tightening bracket guide, a pre-tightening roller, a pre-tightening roller connecting shaft, a pre-tightening torsion spring, and a pre-tightening torsion spring connecting shaft.

[0050] In the spring clamping assembly, the roller rivets pass through the spring connector, the clamping roller, and the roller limiting ring. The clamping spring is a metal spring sheet, which is connected to the front and rear spring connectors through the through hole reserved in the straight section. During the deployment and retraction of the battery array, the winding radial thickness of the bistable composite material support rod changes. The arc section of the clamping spring deforms with the change in radial thickness, and provides radial pressure to the bistable composite material support rod in the reverse winding state through the clamping roller.

[0051] The preload assembly is located at the bottom of the radial clamping constraint mechanism. One end is connected to the spring clamping assembly through the preload bracket guide, and the other end is connected to the stabilizer through the stabilizer bracket. The preload roller is connected to the preload bracket through the preload roller connecting shaft and is tangent to the inner side of the deformation transition zone of the bistable composite material support rod. The preload torsion spring connecting shaft connects the preload bracket and the stabilizer bracket. The preload torsion spring is located on the preload torsion spring connecting shaft, with one end embedded in the round hole of the preload bracket and the other end tangent to the stabilizer bracket, giving the preload roller a certain preload force.

[0052] The deployment and retraction control device includes a deployment and retraction speed control mechanism comprising a tether, a tether fixing ring, a speed control motor, and a rope pulley. The tether fixing ring is installed at both ends of the stabilizer bar, with one end of the tether connected to the tether fixing ring and the other end wound around the rope pulley; the speed control motor is installed on the motor mounting base of the root crossbeam device, and the rope pulley is fixed to the output shaft of the speed control motor by a set screw.

[0053] The root yoke in the root beam device uses rectangular cross-section aluminum profiles. From the outside to the inside of the root yoke, the following components are installed: support rod adjusting seat, support rod pressure strip, tension spring connecting bracket, clamping release device, and motor mounting bracket. Four tension spring connecting brackets are evenly distributed on the root yoke, each with four small holes machined at its front end. One end of a stainless steel tension spring passes through these holes, and the other end passes through a metal clip on the force transmission beam and connects to the sun blanket device. The support rod pressure strip is installed in the middle of the fixed end of the bistable composite material support rod. The middle pressure strip is wider, while the two side strips are narrower. Screws pass through the pre-drilled through holes in the support rod pressure strip, fixing the bistable composite material support rod to the root yoke via the support rod adjusting seat.

[0054] The force transmission beam in the sun blanket device consists of two aluminum strips, one above the other. The surface of the aluminum strips is evenly distributed with round holes. Metal clips pass through the round holes to fix the two aluminum strips. A tension spring passing through the round holes applies the tension load evenly to the flexible substrate. The buffer foam is in the shape of long strips and is attached to the back of the flexible substrate at equal intervals to provide shock absorption and cushioning effect.

[0055] Example:

[0056] like Figure 1 and Figure 2 As shown, this embodiment provides a roll-up flexible solar cell array deployment and retraction mechanism, including a top roll device I, a deployment and retraction control device II, a root crossbeam device III, a pressing and releasing device IV, and a solar blanket device V. The top reel device I is located at the top of the deployment and retraction mechanism, providing support for the deployment and retraction of the flexible substrate 36 in the solar blanket device V and the bistable composite material support rod 7 in the deployment and retraction control device II. The deployment and retraction control device II is symmetrically distributed on both sides of the deployment and retraction mechanism, including the bistable composite material support rod 7, the stabilizing rod 8, the radial clamping constraint mechanism, and the deployment and retraction speed control mechanism. The root crossbeam device III is located at the root of the deployment and retraction mechanism and is connected to the spacecraft body, providing a fixed position for the flexible solar cell array and reserving mechanical and electrical interfaces. The clamping release device IV is installed on the root yoke 31 in the root crossbeam device III, and unlocks the flexible solar cell array by heating the hot knife module 33 to melt the binding rope 32. The solar blanket device V is located inside the rectangular frame composed of the top reel device I, the bistable composite material support rod 7, and the root crossbeam device III. One end is connected to the root yoke 31 by a tension spring 29, and the other end is fixed to the blanket reel 3-1 by screws.

[0057] In this embodiment, the elastic strain energy stored in the bistable composite material support rod 7, which is wound in the opposite direction on the winding shaft 3-2, provides the deployment power for the flexible solar cell array and provides support after full deployment. The radial compression constraint is achieved by the elastic deformation of the compression spring 14 in the radial compression constraint mechanism, which achieves radial compression constraint on the reverse-wound bistable composite material support rod 7. The flexible solar cell array is slowly retracted after deployment by the tether 22 and the speed control motor 24 in the deployment and retraction speed control mechanism.

[0058] like Figure 3 As shown, the top reel device I includes a reel support 1, a clamping arm support 2, a reel tube 3, a mandrel 4, a mandrel bearing 5, and a bearing mounting seat 6. The reel tube 3 includes a middle blanket winding reel 3-1 and two end winding rod reels 3-2. The mandrel 4 passes through the reel support 1 and the mandrel bearing 5 and then through the reel tube 3. One end of the reel support 1 is connected to the mandrel 4, and one end of the clamping arm support 2 is connected to the arm support connecting shaft 9. The other ends of both are connected to the stabilizing rod 8. The clamping arm support 2 changes angle inside the reel support 1 as the flexible solar cell array unfolds. The surface of the winding rod reel 3-2 is milled with flat grooves and drilled with holes to avoid local protrusions and jamming during the winding process. Screws and silicone gaskets are used to fix the extended end of the bistable composite material support rod 7.

[0059] The bistable composite material support rod 7 has a C-shaped cross-section thin-walled slit tube with an opening angle of 300° to 340°. It is made of multi-layer fabric or unidirectional composite prepreg through specific angle lay-up and curing. The forward winding state is one of its stable states. The elastic strain energy stored in its reverse winding state can provide the power for the deployment of flexible solar cell arrays. That is, the lateral and longitudinal curvatures of the rod are reversed, without the need for an additional drive mechanism. Moreover, the composite material has a relatively low coefficient of thermal expansion, which can greatly reduce the space thermal effect.

[0060] like Figure 3 and Figure 4 As shown, the radial clamping constraint mechanism includes an arm support connecting shaft 9, a spring clamping assembly, a pre-tightening assembly, and a stabilizer rod support 21. It is used to constrain the radial natural expansion deformation of the bistable composite material support rod 7 after reverse winding, ensuring tight winding and directional extension. The spring clamping assembly includes a spring connector 10, a clamping roller 11, a roller limiting ring 12, roller male and female rivets 13, and a clamping spring 14. The spring connector 10, according to its configuration, includes a top spring connector 10-1, a middle spring male connector 10-2, a middle spring female connector 10-3, a bottom spring male connector 10-4, and a bottom spring female connector 10-5. The pre-tightening assembly includes a pre-tightening bracket 15, a pre-tightening bracket guide 16, a pre-tightening roller 17, a pre-tightening roller connecting shaft 18, a pre-tightening torsion spring 19, and a pre-tightening torsion spring connecting shaft 20.

[0061] In the spring clamping assembly, the roller rivet 13 passes through the spring connector 10, the clamping roller 11, and the roller limiting ring 12. The spring connectors 10 located in the middle and bottom of the spring clamping assembly are all composed of nested male and female connectors. The number of lugs in the female connector is one more than that in the male connector. The clamping spring 14 is a metal spring sheet that is connected to the front and rear spring connectors 10 through the through hole reserved in the straight section. During the deployment and retraction of the flexible solar cell array, the radial thickness of the bistable composite material support rod 7 changes. The arc section of the clamping spring 14 undergoes elastic deformation as the radial thickness changes. The clamping roller 11 provides radial pressure to the inner side of the bistable composite material support rod 7 in the reverse winding state. The use of the clamping roller 11 can reduce the contact area and the friction during the deployment process.

[0062] The preload assembly is located at the bottom of the radial clamping constraint mechanism. One end is connected to the spring clamping assembly through the preload bracket guide 16, and the other end is connected to the stabilizer 8 through the stabilizer bracket 21. The preload roller 17 is connected to the preload bracket 15 through the preload roller connecting shaft 18. The preload roller 17 is tangent to the inner side of the deformation transition zone of the bistable composite material support rod 7. The preload torsion spring connecting shaft 20 connects the preload bracket 15 and the stabilizer bracket 21. The preload torsion spring 19 is located on the preload torsion spring connecting shaft 20. One end is embedded in the through groove of the preload bracket 15, and the other end is tangent to the stabilizer bracket 21, giving the preload roller 17 a certain preload force.

[0063] like Figure 3 and Figure 5 The deployment and retraction speed control mechanism in the deployment and retraction control device II includes a tether 22, a tether fixing ring 23, a speed control motor 24, and a rope pulley 25. The tether fixing ring 23 is installed at both ends of the stabilizing rod 8. One end of the tether 22 is fixed to the tether fixing ring 23, and the other end is wound around the rope pulley 25. The speed control motor 24 is installed on the motor mounting base 26 of the root crossbeam device III. Two speed control motors 24 are controlled by one controller to achieve synchronized speeds. The rope pulley 25 is fixed to the output shaft of the speed control motor 24 by a set screw. Specifically, the tether 22 is tensioned by adjusting the forward and reverse rotation of the motor. The tether 22 tightens the stabilizing rod, thereby completing the deployment speed control and retraction process of the flexible solar array.

[0064] In another embodiment of the invention where there is no need for retraction, the tether 22 and the speed control motor 24 can be omitted, and speed dampers can be installed only at both ends of the spindle bearing 5 mounted on the reel tube 3 to control the deployment speed and reduce deployment impact and flexible vibration.

[0065] like Figure 5As shown, the root yoke 31 is made of rectangular cross-section aluminum profile. From the outside to the inside, it is equipped with a support rod adjustment seat 28, a support rod pressure strip 27, a tension spring connecting frame 30, a clamping release device IV, and a motor mounting seat 26. The support rod pressure strip 27 is installed in the middle of the fixed end of the bistable composite material support rod 7. The middle pressure strip is wider, and the two side pressure strips are narrower. Screws are used to pass through the pre-drilled holes in the support rod pressure strip 27 to fix the bistable composite material support rod 7 to the root yoke 31 through the support rod adjustment seat 28. Four tension spring connecting frames 30 are evenly distributed on the root yoke 31. Four small holes are machined at the front end to adjust the tension to different degrees. One end of the stainless steel tension spring 29 passes through the small hole, and the other end passes through the metal clip on the force transmission beam 35 and is connected to the sun blanket device V.

[0066] Furthermore, the clamping release device IV includes a binding rope 32, a hot knife module 33, and a hot knife module mounting base 34. When the flexible solar cell array is stored, the binding rope 32 passes through the wire groove of the hot knife module mounting base 34 to bind the reel tube 3; when the flexible solar cell array is unfolded, the resistor in the hot knife module 33 is energized and heats up, melting the binding rope 32 and unlocking the mechanism.

[0067] Furthermore, the force transmission beam 35 consists of two aluminum strips, one above the other. Two rows of eight round holes are evenly distributed on the surface of the aluminum strips. Metal clips pass through the round holes to fix the two aluminum strips. Four tension springs 29 passing through the round holes apply the tension load evenly to the flexible substrate 36. The flexible substrate 36 is made of polyimide film and fiber fabric through a molding composite process. The cushioning foam 37 is long and strip-shaped and is attached to the back of the flexible substrate 36 at equal intervals to provide shock absorption and cushioning effect. The relative thickness of the solar blanket device V and the relative thickness of the bistable composite material support rod 7 are adjusted to be consistent so that the same length is extended or retracted when the unit number of turns is wound. The front side of the flexible substrate 36 is used to mount solar cells.

[0068] The working process of the roll-up flexible solar cell array deployment and take-up mechanism in this embodiment is as follows:

[0069] Step 1: The flexible solar array reaches the predetermined position in space, and the onboard computer or ground control station issues an unlocking command.

[0070] Step 2: After receiving the unlocking command, the electronic control system of the flexible solar cell array deployment and retraction mechanism is activated, the clamping and release device IV is started, the hot knife module 33 is energized to burn off the binding rope 32, and the reel tube 3 is released.

[0071] Step 3: The onboard power supply powers the speed control motor 24. The motor 24 starts working and drives the rope wheel 25 to rotate in the forward direction. The tether 22 pulls the stabilizing rod 8 and releases it at a constant speed. The bistable composite material support rod 7 moves in the specified direction by relying on its own elastic strain energy and the constraint of the radial compression constraint mechanism, which drives the solar blanket device V to unfold synchronously. The tension spring 29 applies a uniform tension load to the solar blanket device V through the force transmission beam 35.

[0072] Step 4: After the sun blanket device V is fully deployed, the speed control motor 24 stops supplying power, and the structure is provided by two bistable composite material support rods 7.

[0073] Step 5: If necessary, the speed control motor 24 is powered on again to drive the rope wheel 25 to rotate in the opposite direction. The stabilizing rod 8 is slowly retracted by the tether rope 22, and finally the flexible solar cell array is deployed and retracted.

Claims

1. A roll-up flexible solar cell array deployment and retraction mechanism, characterized in that, It includes a top roll assembly, an unfolding and retracting control assembly, a root crossbeam assembly, a clamping and releasing assembly, and a sun blanket assembly; The top roll assembly, located at the top of the unfolding and retracting mechanism, includes a roll support, a clamping arm support, a roll tube, a mandrel, a mandrel bearing, and a bearing mounting base; the roll tube includes a blanket winding roll and a rod winding roll; the mandrel passes through the roll support and the mandrel bearing and extends through the roll tube; the top roll assembly provides support for the unfolding and retraction of the sun blanket device; The deployment and retraction control device is symmetrically distributed on both sides of the deployment and retraction mechanism, including a bistable composite material support rod, a stabilizing rod, a radial clamping constraint mechanism, and a deployment and retraction speed control mechanism. The bistable composite material support rod is wound in the opposite direction on a winding reel, utilizing the strain energy stored in the winding reel itself to provide deployment power and providing rigid support after full deployment. One end of the radial clamping constraint mechanism is connected to a clamping arm support via an arm support connecting shaft, and the other end is connected to the stabilizing rod, constraining the radial natural expansion deformation of the reverse-wound bistable composite material support rod, allowing it to wind and achieve directional extension. The deployment and retraction speed control mechanism controls the deployment time of the battery array and enables the battery array to retract after deployment. The root crossbeam device, located at the root of the deployment and retraction mechanism and connected to the spacecraft body, includes a motor mounting base, support rod pressure strip, tension spring, tension spring connecting frame, reel limiting component and root yoke, providing a fixed position for mounting the battery array and reserving mechanical and electrical interfaces; The clamping release device is installed on the root yoke in the root crossbeam device and includes a binding rope, a hot knife module, and a hot knife module mounting base. When the battery array is stored, the binding rope passes through the wire groove of the hot knife module mounting base and binds the reel tube to the reel limiter of the root crossbeam device. When the battery array is unfolded, the resistor in the hot knife module is energized and heats up, melting the binding rope and unlocking the mechanism. The sun blanket device is located inside a rectangular frame consisting of a top roll assembly, a bistable composite material support rod, and a root crossbeam assembly. It includes a force transmission beam, a flexible substrate, and cushioning foam. One end of the force transmission beam is connected to the root crossbeam assembly via a tension spring, and the other end is wound around the blanket roll in the top roll assembly. One end of the roller bracket in the top roller device is connected to the spindle; the angle of the clamping arm bracket is variable, and one end is connected to the arm bracket connecting shaft; the other ends of both the roller bracket and the clamping arm bracket are connected to the stabilizing rod. The radial clamping constraint mechanism includes an arm support connecting shaft, a spring clamping assembly, a pre-tightening assembly, and a stabilizer bar support; the spring clamping assembly includes a spring connector, a clamping roller, a roller limiting ring, roller male and female rivets, and a clamping spring; the spring connector, according to its configuration, includes a top spring connector, a middle spring male connector, a middle spring female connector, a bottom spring male connector, and a bottom spring female connector; the pre-tightening assembly includes a pre-tightening bracket, a pre-tightening bracket guide, a pre-tightening roller, a pre-tightening roller connecting shaft, a pre-tightening torsion spring, and a pre-tightening torsion spring connecting shaft; The roller rivet passes through the spring connector, the pressure roller, and the roller limiting ring; the pressure spring is... The metal spring is connected to the front and rear spring connectors through the through holes reserved in the straight section. During the deployment and retraction of the battery array, the radial thickness of the bistable composite material support rod changes. The arc section of the clamping spring deforms with the change in radial thickness, and the clamping roller provides radial pressure to the bistable composite material support rod in the reverse winding state. The preload assembly is located at the bottom of the radial clamping constraint mechanism. One end is connected to the spring clamping assembly via the preload bracket guide, and the other end is connected to the stabilizer rod via the stabilizer rod bracket. The preload roller is connected to the preload bracket via the preload roller connecting shaft and is tangent to the inner side of the deformation transition zone of the bistable composite material support rod. The preload torsion spring connecting shaft connects the preload bracket and the stabilizer rod bracket. The preload torsion spring is located on the preload torsion spring connecting shaft, with one end embedded in the round hole of the preload bracket and the other end tangent to the stabilizer rod bracket, providing a certain preload force to the preload roller. The speed control mechanism for extending and retracting includes a tether rope, a tether rope fixing ring, a speed control motor, and a rope wheel; the tether rope fixing ring is installed at both ends of the stabilizer bar, one end of the tether rope is connected to the tether rope fixing ring, and the other end is wound around the rope wheel; the speed control motor is installed on the motor mounting base of the root crossbeam device; the rope wheel is fixed to the output shaft of the speed control motor by a set screw; The root yoke is equipped with a support rod adjusting seat, a support rod pressure strip, a tension spring connecting frame, a clamping release device, and a motor mounting seat from the outside to the inside. Multiple tension spring connecting frames are evenly distributed on the root yoke. Each tension spring connecting frame has multiple small holes machined at its front end. One end of a stainless steel tension spring passes through these small holes, and the other end passes through a metal clip on the force transmission beam and connects to the sun blanket device. The support rod pressure strip is installed in the middle of the fixed end of the bistable composite material support rod, with the width of the middle strip being greater than the widths of the two side strips. Screws pass through the pre-drilled through holes in the support rod pressure strip, fixing the bistable composite material support rod to the root yoke via the support rod adjusting seat.

2. The roll-up flexible solar cell array deployment and retraction mechanism according to claim 1, characterized in that, The surface of the winding spool is milled with a planar groove and drilled with holes to fix the extended end of the bistable composite material support rod.

3. The roll-up flexible solar cell array deployment and retraction mechanism according to claim 1, characterized in that, The bistable composite material support rod is configured as a C-shaped cross-section thin-walled slit tube, which is made of multi-layer ultra-thin fabric or unidirectional composite fiber-reinforced prepreg through specific angle lay-up and curing. It utilizes the elastic strain energy stored in its reverse-wound state to provide power for the deployment of the battery array without the need for an additional drive mechanism.

4. The roll-up flexible solar cell array deployment and retraction mechanism according to claim 1, characterized in that, The root yoke is made of rectangular cross-section aluminum profile or rectangular honeycomb sandwich panel.

5. The roll-up flexible solar cell array deployment and retraction mechanism according to claim 1, characterized in that, There are four tension spring connecting frames, which are evenly distributed on the root yoke. The front end of the tension spring connecting frame is machined with four small holes.

6. The roll-up flexible solar cell array deployment and retraction mechanism according to claim 1, characterized in that, The force transmission beam consists of two aluminum strips, one above the other. The surface of the aluminum strips is evenly distributed with round holes. Metal clips pass through the round holes to fix the two aluminum strips. Tension springs passing through the round holes apply the tension load evenly to the flexible substrate.

7. The roll-up flexible solar cell array deployment and retraction mechanism according to claim 1, characterized in that, The cushioning foam is in the form of long strips and is made of high-temperature resistant polyimide material. It is attached to the back of the flexible substrate at equal intervals to provide shock absorption and cushioning effect.

8. A method for deploying and retracting the roll-up flexible solar cell array deployment and retraction mechanism as described in claim 1, characterized in that, The specific steps are as follows: Step 1: Once the flexible solar array reaches its designated location in space, the onboard computer or ground control station issues an unlocking command; Step 2: Upon receiving the unlocking command, the electronic control system of the flexible solar cell array deployment and retraction mechanism is activated, the clamping and release device is activated, the hot knife module is energized to burn off the binding rope, and the reel tube is released. Step 3: The onboard power supply supplies power to the speed control motor. The speed control motor starts to work and drives the rope wheel to rotate in the forward direction. The tethered traction stabilizer is released at a constant speed. The bistable composite material support rod moves in the specified direction by relying on its own elastic strain energy and the constraint of the radial compression constraint mechanism, which drives the solar blanket device to unfold synchronously. The tension spring applies a uniform tension load to the solar blanket device through the force transmission beam. Step 4: After the sun blanket device is fully deployed, the speed control motor stops supplying power, and the structure is supported by two bistable composite material support rods. Step 5: When retracting, the speed control motor is powered on again, causing the rope wheel to rotate in the opposite direction. The stabilizing rod is pulled back by the tether rope, and finally the flexible solar cell array is deployed and retracted.

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