High-stiffness reconfigurable surfaces based on bistable element assembly and bi-compatible truss attachment

Reconfigurable surfaces contribute to multi-task robotic platforms, such as reconfigurable phased array antennas with variable aperture, by morphing between multiple specified shapes. Controlling each tile to approximate the variating shape of target surfaces requires a large number of accurate actuators. Previous research has demonstrated employing bistable-element-assembly to form reconfigurable surfaces for significant actuation simplification but suffering from low out-of-plane stiffness resulting in the lack of load-bearing capacity for carrying functional units with good mechanical accuracy. This paper proposes a design framework for tile-assembling bistable (TAB) surfaces with bi-compatible truss attachment for two prescribable stable configurations. The bistability comes from joining surface tiles with bistable elements, which contributes to easy actuation with fewer inaccurate actuators. Bi-compatible truss structures, which are only kinematically compatible at the two prescribed states, are introduced to enhance the out-of-plane stiffness of the TAB surface and improve its load-bearing capacity. Additionally and consequently, the kinematic determinacy of the reconfigurable surfaces is increased by the truss introduction, where bistable elements control the metric while truss structures dictate the principal curvature of the surface. This diminishes the redundant degrees of freedom with enhanced shape-approximation and reconfiguration-coordination. Four prototypes are designed and manufactured, which are a three-tile by three-tile (3 × 3) TAB surface that is stable at flat and spherical configurations, a 5 × 5 TAB surface with flat and spherical stable configurations, a 3 × 3 TAB surface that is stable at the flat and saddle configurations, and a 3 × 3 TAB surface that is stable at the sphere and saddle shapes. The out-of-plane stiffness, easiness of actuation, and shape accuracy of all prototypes are evaluated and show promises for real engineering applications.