Developing Hybrid Thickness-Accommodation Techniques for New Origami-Inspired Engineered

98 Pages·2017·12.23 MB·English

Brigham Young University
BYU ScholarsArchive
All Theses and Dissertations
2017-05-01
Developing Hybrid Thickness-Accommodation
Techniques for New Origami-Inspired Engineered
Systems
Kyler Austin Tolman
Brigham Young University
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Tolman, Kyler Austin, "Developing Hybrid Thickness-Accommodation Techniques for New Origami-Inspired Engineered Systems"
(2017).All Theses and Dissertations. 6360.
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DevelopingHybridThickness-AccommodationTechniquesforNew
Origami-InspiredEngineeredSystems
KylerAustinTolman
Athesissubmittedtothefacultyof
BrighamYoungUniversity
inpartialfulfillmentoftherequirementsforthedegreeof
MasterofScience
LarryL.Howell,Chair
SpencerP.Magleby
R.DanielMaynes
DepartmentofMechanicalEngineering
BrighamYoungUniversity
Copyright©2017KylerAustinTolman
AllRightsReserved
ABSTRACT
DevelopingHybridThickness-AccommodationTechniquesforNew
Origami-InspiredEngineeredSystems
KylerAustinTolman
DepartmentofMechanicalEngineering,BYU
MasterofScience
Origami has become a source of inspiration in a number of engineered systems. In most
systems, non-paper materials where material thickness is non-negligible is required. In origami-
inspired engineered systems where thickness is non-negligible, thickness-accommodation tech-
niquesmustbeutilizedtoovercometheissueofself-intersection. Manythickness-accommodation
techniques have been developed for use in thick-origami-inspired-engineered systems. In this
work several thickness-accommodation techniques are reviewed and discussed. New thickness-
accommodation techniques including hybrid thickness-accommodation techniques and the split
vertextechniquearepresentedanddiscussed. Thesetechniquesenablenewcapabilitiesofthickness-
accommodation in origami adapted design. Thickness-accommodation techniques have been de-
veloped in the context of developable origami patterns and the application of these techniques to
non-developable patterns is introduced here. The capability of non-developable thick origami is
demonstratedinanapplicationexampleofadeployablelocomotivenose-fairing.
Keywords: Origami,DeployableMechanisms,CompliantMechanisms
ACKNOWLEDGMENTS
I would first like to acknowledge and express appreciation for my graduate committee
members Dr. Larry Howell, Dr. Spencer Magleby, and Dr. Daniel Maynes for their expertise,
inspiration,andguidancethroughouttheprocessofmyresearch. Iwouldalsoliketoacknowledge
andthankDr. RobertLangforhisinspirationandcollaborativeeffortsinmyresearch.
I would also like to acknowledge and express thanks to the many members of the Compli-
ant Mechanisms Research Group (CMR) who have helped me with my research and collaborated
on the papers that are presented here. Namely I would like to thank Erica Crampton for her col-
laboration on the thick origami review paper and locomotive fairing project, Chad Stucki and Jeff
Niven for their collaboration on the foldable fairing project, Alden Yellowhorse for his collabora-
tion on the non-developable origami work, and Michael Morgan for his work on the offset-panel
technique which led into my work on hybrid-thickness-accommodation techniques. I would also
liketothanktheothermembersoftheCMRwhoIhavehadtheprivilegeofworkingtogetherwith
onvariousprojectsandpublicationsthatarenotincludedinthisthesis.
Finally I would like to thank my family for their continued support and encouragement
throughout my schooling. I would like to express appreciation for my wife Ann for her love,
support, and patience with me on this journey. Her determination to help me become a better
personiswhatpersuadedmetopursuegraduateschool.
This work is based upon research supported by funding from the National Science Foun-
dation and the Air Force Office of Scientific Research under Grant No. 1240417. Any opinions,
findings,andconclusionsorrecommendationsexpressedinthisthesisarethoseoftheauthorsand
donotnecessarilyreflecttheviewsoftheNationalScienceFoundation.
TABLEOFCONTENTS
LISTOFTABLES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . vi
LISTOFFIGURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . vii
Chapter1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Chapter2 AReviewofThickness-AccommodationTechniques . . . . . . . . . . . . 4
2.1 TaperedPanelsTechnique . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
2.2 OffsetPanelTechnique . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
2.3 HingeShiftTechnique . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
2.4 DoubledHingeTechnique . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
2.5 RollingContactsTechnique . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
2.6 MembraneTechnique . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
2.7 StrainedJointTechnique . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Chapter3 HybridTechniques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
3.1 CombiningTechniques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
3.2 RollingContact/DoubledHingeComposite . . . . . . . . . . . . . . . . . . . . . 24
3.3 OffsetPanel/HingeShiftHybrid . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
3.4 OffsetPanel/DoubledHingeHybrid . . . . . . . . . . . . . . . . . . . . . . . . . 28
3.5 DoubledHinge/HingeShiftHybrid . . . . . . . . . . . . . . . . . . . . . . . . . . 29
3.6 OtherHybridandCompositeTechniques . . . . . . . . . . . . . . . . . . . . . . . 30
Chapter4 Split-VertexTechnique . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
4.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
4.2 Background . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
4.3 Split-VertexTechnique . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
4.3.1 CompatiblePatterns . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
4.3.2 SplittingCreases . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
4.3.3 SplitAngles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
4.3.4 SplitDistance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
4.3.5 AddressingIntersection . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
4.3.6 ApplyingtheSplit-VertexTechnique . . . . . . . . . . . . . . . . . . . . . 44
4.4 Discussion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
4.5 Conclusions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
Chapter5 Thickness-AccommodationinNon-DevelopableOrigami . . . . . . . . . . 50
5.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
5.2 Background . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
5.3 Non-developableorigami . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
5.4 Non-developableThickOrigami . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
5.4.1 TaperedandOffset-Paneltechniques . . . . . . . . . . . . . . . . . . . . . 54
iv
5.4.2 Axis-shifttechnique . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
5.4.3 Split-vertextechnique . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
5.5 Conclusions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
Chapter6 DesignofanOrigami-InspiredDeployableAerodynamic
LocomotiveFairing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
6.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
6.2 Background . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
6.2.1 ThickOrigami . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
6.3 Approach . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
6.4 ConceptGeneration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
6.5 ConceptEvaluation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
6.5.1 Flat-panel-basedconcept . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
6.5.2 Fabric-basedconcept . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
6.6 ConceptSelection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
6.7 DesignOptimization . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
6.8 FinalFairingDesign . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
6.9 DesignValidationthroughFull-ScalePrototype . . . . . . . . . . . . . . . . . . . 78
6.10 Conclusion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
Chapter7 Conclusion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
7.1 Conclusions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
7.2 FutureWork . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
REFERENCES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
v
LISTOFTABLES
4.1 Comparisonofdifferentattributesofsomethickness-accommodationtechniques. . 47
vi
LISTOFFIGURES
2.1 TaperedpanelstechniqueappliedtotheMiura-oripattern. . . . . . . . . . . . . . 5
2.2 Thetaperedpanelstechnique. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
2.3 Diagramdetailingthelengthofapanel’staper. . . . . . . . . . . . . . . . . . . . 6
2.4 Theoffsetpaneltechnique. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
2.5 Asingleoffsetpanelvertex. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
2.6 Thehingeshifttechnique. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
2.7 AthickfoldingvertexdemonstratedbyHobermanfortheMiura-oripattern. . . . 10
2.8 Photosofathickenedrigidly-foldablearcpatternprototypecreatedusingsymmet-
ricdegree-4verticesshownmovingfromflattofolded. . . . . . . . . . . . . . . . 11
2.9 TheslidinghingeapproachdemonstratedbyTrautzetal. . . . . . . . . . . . . . . 11
2.10 AthickfoldingvertexdemonstratedbyDeTemmermanfortheYoshimurapattern. 11
2.11 Photos of a thick folding Yoshimura pattern prototype comprised of symmetric
degree6vertices. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
2.12 A thick rigidly foldable square twist developed using the generalized hinge shift
techniqueofChenetal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
2.13 AgeneralizedthickfoldingvertexdemonstratedbyChenetal. . . . . . . . . . . . 14
2.14 Thedoubledhingetechnique(offsetcreaseimplementation). . . . . . . . . . . . . 15
2.15 An offset crease implementation of the doubled hinge technique demonstrated for
asingledegree-4vertex. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
2.16 Therollingcontactstechnique(SORCEimplementation). . . . . . . . . . . . . . . 16
2.17 AprototypeofthickvertexutilizingSORCEtechniquedemonstratedbyLangetal. 18
2.18 Themembranetechnique. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
2.19 Thestrainedjointtechnique. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
2.20 Thestrainedjointtechniqueappliedtoadegree4vertex. . . . . . . . . . . . . . . 21
3.1 An implementation of the doubled hinge technique where the vertex is only split
alongtheprimaryfoldaxis. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
3.2 Arollingcontact/doubledhingecompositevertexwheretraditionalhingesareused
togetherwithrollingcontactjoints. . . . . . . . . . . . . . . . . . . . . . . . . . . 25
3.3 Aprototypeofrollingcontact/doubledhingecompositevertex. . . . . . . . . . . . 25
3.4 Theoffsetpanel/hingeshifthybridtechnique. . . . . . . . . . . . . . . . . . . . . 25
3.5 Apatternconsistingoftwodegree-4vertices. . . . . . . . . . . . . . . . . . . . . 26
3.6 Anoffsetpanel/hingeshifthybridmechanism. . . . . . . . . . . . . . . . . . . . . 27
3.7 AYoshimurapatterncreatedusingoffsetpanel/hingeshifthybridtechniqueshown
deployedandfolded. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
3.8 Abird-basepatterncreatedusingoffsetpanel/hingeshifthybridtechnique. . . . . 28
3.9 Atwo-vertexpatternwheretheleftvertexhasthecreasedoubled. . . . . . . . . . 28
3.10 A hybrid mechanism where the right vertex utilizes the offset panel technique and
theleftvertexutilizesthedoubledhingetechnique. . . . . . . . . . . . . . . . . . 29
3.11 Adoubledhinge/hingeshifthybridmechanism. . . . . . . . . . . . . . . . . . . . 30
4.1 Adegree4vertexwithsectorandfoldangleslabeled. . . . . . . . . . . . . . . . 33
4.2 Anonflat-foldabledegree4vertexinitsfoldedstatewithfoldangleslabeled. . . . 34
vii
4.3 Theoffset-creasetechnique. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
4.4 Thesplit-vertextechnique. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
4.5 A comparison of the (a) offset-crease technique and (b) split-vertex technique for
asinglevertex. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
4.6 Asymmetric,split-crease-compatible,two-vertexsystem(left)andanon-symmetric,
non-compatible,two-vertexsystem(right). . . . . . . . . . . . . . . . . . . . . . . 38
4.7 Splitting of a degree 4 vertex. Flat folding un-split single vertex (left) and split
vertexwithnewparameterslabeled(right). . . . . . . . . . . . . . . . . . . . . . 38
4.8 Fold angles γ and γ as a function of split angle β for the example vertex shown
1 3 1
inFigure4.7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
4.9 Spacer angle µ as a function of split angle β for the example vertex shown in
1
Figure4.7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
4.10 Splitdistancesd andd . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
1 2
4.11 Split-vertextechniquewithalternativeinterferenceaccommodationmethod. . . . . 44
4.12 Split-vertextechniqueappliedtohexagonpattern. . . . . . . . . . . . . . . . . . . 46
4.13 CADmodelofsplit-vertexhexagonpatterngoingthroughfoldingmotion. . . . . . 46
4.14 Monolithicprototypeofsplit-vertexhexagonpatternmachinedoutofpolypropylene. 46
4.15 Split-vertextechniqueappliedtobirdbasepattern. . . . . . . . . . . . . . . . . . 47
4.16 Prototype of split-vertex bird base thick origami mechanism fabricated from foam
boardandredpolypropylenetape,demonstratingaflatsurfacewithnoholes. . . . 47
4.17 Rigidly-foldable square patterns realized using the split-vertex technique. Top:
square twist based fold pattern. Bottom: straight-major square-twist pattern. The
redsurfacedemonstratestheabilitytocreateaflatsurfacewithnoholes. . . . . . . 48
5.1 A developable degree-4 vertex in its unfolded state (left) and partially folded state
(right). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
5.2 Anunder-developeddegree-4vertexgoingthroughitsfoldingmotion. . . . . . . . 53
5.3 Anover-developeddegree-4vertexgoingthroughitsfoldingmotion. . . . . . . . . 53
5.4 Anunder-developedhexagonpatternmodifiedusingtheoffset-paneltechnique. . . 55
5.5 Anunder-developedboxpatternmodifiedusingtheoffset-paneltechnique. . . . . 56
5.6 Anexampleaxis-shiftvertex. Hingesareindicatedbyreddashedlines. . . . . . . 57
5.7 A symmetric-compliment-type Bennett linkage where opposing twist angles are
notequalbutarecompliments. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
5.8 A symmetric Bennett linkage where opposing links have equal lengths and twist
angles. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
5.9 Foam-boardprototypeofsymmetric-non-developable-thicktube. . . . . . . . . . . 58
5.10 The three different linkages used in the symmetric-thick-origami tube. Left: an
under-developed-traditional-Bennett linkage. Center: a developable compliment-
typeBennettlinkage. Right: anover-developed-traditional-Bennettlinkage. . . . . 59
5.11 Foam-boardprototypeofnon-symmetricnon-developable-thicktube. . . . . . . . 59
5.12 Eggboxpatterncomprisedofover-developedBennettlinkagesandunder-developed
sphericallinkages. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
5.13 Eggboxinspirednon-developabletubecomprisedofexcess-vertexBennetlinkages
anddeficient-vertexsphericallinkages. . . . . . . . . . . . . . . . . . . . . . . . . 61
5.14 Split-verteximplementationofanon-developablehexagonpattern. . . . . . . . . . 62
viii
6.1 Initial concept for an origami-inspired deployable fairing based on rigid folding
panels. Left: The fairing in its deployed state. Right: the fairing in its stowed
(folded)state. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
6.2 Adegree-4vertex. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
6.3 Anexampleoffset-panelvertex. Hingesareindicatedbyreddashedlines. . . . . . 68
6.4 Anexampleaxis-shiftvertex. Hingesareindicatedbyreddashedlines. . . . . . . 69
6.5 Designvolumeforthedeployedfairing. Usableareaishighlightedinyellow. . . . 69
6.6 Design volume for the fairing in the stowed configuration. Usable area is high-
lightedinyellow. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
6.7 Fabric-based design concepts. Left: inflatable fairing concept sketch. Right:
tension-fabric-basedfairingconcept. . . . . . . . . . . . . . . . . . . . . . . . . . 71
6.8 Proof-of-conceptprototypeofthenon-developableorigami-basedflatpaneldesign. 72
6.9 Scaledprototypeoftension-fabricconcept. . . . . . . . . . . . . . . . . . . . . . 73
6.10 Parametersusedinthefirststudy(left)andthesecondstudy(right). . . . . . . . . 74
6.11 OptimizedshapeofthefirstCFDstudy. . . . . . . . . . . . . . . . . . . . . . . . 74
6.12 OptimizedshapeofthesecondCFDstudy. . . . . . . . . . . . . . . . . . . . . . . 75
6.13 Simplified shape that gives performance similar to the curved shape of the second
study. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
6.14 Fold pattern of the non-developable fairing design. Red lines indicate where the
face panel attaches to the side panel. Green lines indicate where the panels attach
totheframe. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
6.15 Eighth-scaleprototypeconstructedfromsheetmetal. . . . . . . . . . . . . . . . . 77
6.16 Composite high-strength steel and HDPE foam sandwich panel selected as the
panelmaterialforthefullscalefairingdesign. . . . . . . . . . . . . . . . . . . . . 78
6.17 Full-scale prototype on a freight locomotive shown in both the stowed configura-
tion(right)anddeployedconfiguration(right). Photohasbeenmodifiedtoremove
locomotiveidentity. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
6.18 Thetopofthefairingstands3.6meterstallfromtheground. An158cmtallperson
providesavisualindicationofthefairingsize. Photohasbeenmodifiedtoremove
locomotiveidentity. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
ix