{ "id": "origami-bench-01", "status": "Proposed experiments — no physical article built or tested", "objective": "Demonstrate a truly synchronized finite-thickness deployable utility canopy, then independently prove compliant pneumatic skin actuation and source-specific removable drainage.", "proposedDimensions": { "fullScaleLeafPitchM": 0.5, "fullScaleRigidLeafM": [0.45, 0.012, 1.5], "leafCount": 6, "foldAngleRangeDeg": [15, 70], "benchScale": 0.5, "benchLeafPitchM": 0.25, "benchRigidLeafM": [0.225, 0.006, 0.75], "benchEndTrimM": 0.0125, "benchDeployedSpanM": 1.448889, "benchPackedSpanM": 0.513030, "intermediateLeafTimingTransmissions": 4, "guideTracks": 2, "skinMaterialScreenCouponM": [0.14, 0.2], "skinIntegrationCouponM": [0.44, 0.6], "benchNote": "Scale is proposed; actual stiffness, buckling, friction and wind do not obey simple visual scale. No full-scale structural qualification follows from the bench." }, "mechanicalCoupling": { "configuration": "Four open equal-pulley belts on intermediate leaves 1–4; root and tip shafts keyed to neighboring leaves, not the carrying leaf. Adjacent belt planes stagger axially.", "equations": [ "beta_i = alpha_i - alpha_(i-1)", "root pulley rotation relative to carrying leaf i = -beta_i", "tip pulley rotation relative to carrying leaf i = beta_(i+1)", "equal open-belt transmission: beta_(i+1) = -beta_i", "fixed endpoint height: sin A + sin(A+B) = 0; selected branch A=-B/2", "end x=N*l*cos(theta); do not independently command carriage and hinges" ], "unresolved": "Detailed keyed sleeves, bearing stack, tensioners, guards, tolerance accumulation, real belt compliance and backdrive response remain mechanical design work." }, "bom": [ {"item": "Repeated rigid leaf cassettes", "quantity": 6, "specification": "Bench 225 × 750 mm solids, nominal 6 mm total thickness, 250 mm pivot pitch. Weigh each; choose a benign machined sheet or sandwich coupon before PV payload."}, {"item": "Interleaved hinge sets", "quantity": 7, "specification": "Retained axle, replaceable bushings and axially separated knuckles; include mounting tabs and guards in clearance coupon. Seven pivot lines include both ends."}, {"item": "Equal-pulley synchronization transmissions", "quantity": 4, "specification": "Eight same-tooth-count pulleys, four open belts, neighbor-keyed sleeves and independent tension adjustment. Supplier tooth/belt ratings must be selected from measured torque."}, {"item": "Ground guides and moving portal", "quantity": 1, "specification": "Two parallel 1.7 m bench rails, four guide wheels, rigid portal, end stops and alignment adjustment; no occupancy below rig."}, {"item": "Force-limited manual drive and optional geared motor", "quantity": 1, "specification": "Start with hand drive and inline load cell. Optional 24 V drive only after kinematic and jam tests; full-scale 100 W/250 N numbers are sizing assumptions, not bench limits."}, {"item": "Separate brake and manual recovery", "quantity": 1, "specification": "Power-loss hold, guarded manual drive, no automatic restart. Gear self-locking alone is not accepted as a safety brake."}, {"item": "Positive carriage lock sets", "quantity": 2, "specification": "Retained pins plus designed receivers and independent engagement witnesses; do not transfer a catalog access-latch rating to this load path."}, {"item": "Angle, displacement and force instrumentation", "quantity": 1, "specification": "Six optical angle targets or calibrated encoders, carriage ruler/linear encoder, load cell, electrical power meter, synchronized camera, backlash indicator and data log."}, {"item": "Independent emergency stop / motion interlocks", "quantity": 1, "specification": "Hardwired motor cutoff, brake state, two end switches, force/current cutoff, manual reset and drain-disconnect state. No cloud service or learned controller in safety chain."}, {"item": "Removable valley drains and ground manifold", "quantity": 4, "specification": "One drain at lower pivot positions 0/2/4/6; defined cross-width slope, unions and drainable ground hoses; only installed after mechanical lock."}, {"item": "Rainfall collection measurements", "quantity": 1, "specification": "Metered spray supply, first-flush vessel, buffer scale, overflow/reject vessels, splash containment; all water nonpotable."}, {"item": "Skin laminate material screening sets", "quantity": 3, "specification": "140 × 200 mm coupons screening equal, 2:1 and 4:1 relative flexural-stiffness layouts. Compare FRP/elastomer or thermoplastic candidates; do not copy a pressure limit from FlectoLine."}, {"item": "Breathing skin integration coupon", "quantity": 1, "specification": "440 × 600 mm proposed asymmetric laminate with integrated air cushion, edge clamp and removable service dock; PV islands only after strain is mapped."}, {"item": "Guarded low-pressure skin test circuit", "quantity": 1, "specification": "Low-volume supply, rated regulator, independent mechanical relief, vent, pressure transducer and transparent protective enclosure. Fixture/material pressure assessment precedes energizing."}, {"item": "Replaceable skin electrical islands", "quantity": 1, "specification": "Initial inert masses / strain markers, then isolated PV segments away from measured curvature; meter energy and inspect joints."}, {"item": "Keyed service-dock coupon", "quantity": 1, "specification": "Asymmetric locating rails, distinct wet/dry interfaces and separate retained pin; use original geometry rather than unlicensed Tsugite software."}, {"item": "Protective equipment and dust containment", "quantity": 1, "specification": "Pinch guards, exclusion perimeter, shielded cycling fixture and controlled dust containment. No deliberate hand-in-jam test."} ], "planningCost": { "currency": "USD", "range": [1800, 5200], "basis": "Authored planning allowance for instrumented bench mechanism plus separate skin and drainage coupons; not supplier quotes. No purchase or spending occurred for these artifacts.", "excludes": ["engineering labor", "full-scale roof fabrication", "certified wind/snow/foundation design", "full PV installation", "environmental chamber", "long-duration outdoor and regulatory qualification", "novel material tooling beyond simple coupons"], "procurementGate": "Obtain current fabrication, belt/shaft, sensor and laminate quotes; retain part ratings and safety data before procurement." }, "experiments": [ { "id": "E1-clearance", "name": "Finite-thickness two-leaf coupon", "method": "Build selected panel skins/core, root/tip tabs, actual bushings, cable loops and guard. Sweep 15–70° in both directions; measure gaps at each 5° step and at closest approach.", "measurements": ["minimum solid clearance", "torque-angle curve", "bushing play", "cable minimum curvature", "retained-pin security"], "passCriteria": ["No unintended contact or loss of pin retention", "Documented positive clearance under specified tolerances; 25 mm full-scale trim alone is not proof", "Cable meets the selected manufacturer's dynamic bend-radius data throughout travel"], "disconfirmingResult": "Mount tabs, guards, seals or cable loops collide despite panel-corner clearance; revise geometry before the six-leaf build.", "status": "Not run" }, { "id": "E2-synchronization", "name": "Four-transmission one-DoF branch", "method": "Install neighbor-keyed equal pulleys and open belts; constrain the end hinge to fixed height. Backdrive slowly from one end with motor disconnected; optically measure all six leaf angles and carriage position.", "measurements": ["all absolute and relative angles", "end height and span", "reversal backlash", "belt tension", "drive force"], "passCriteria": ["Proposed screening target: less than 1° absolute alternating-angle tracking error", "Proposed bench carriage target: within ±2 mm of 1.5 cos(theta) m", "No tooth jump, binding, branch change or uncommanded motion on reversal"], "disconfirmingResult": "Equal-angle animation cannot be physically reproduced with the chosen shaft/belt/bearing layout or under unequal joint friction.", "status": "Not run" }, { "id": "E3-jam-brake", "name": "Drive loss and obstruction", "method": "With guarded, unoccupied rig, interrupt power at 5° angle steps; block one wheel remotely and increase one hinge's friction in a measured manner. Confirm independent stop/hold and manual recovery.", "measurements": ["stopping displacement", "peak force/current", "hold drift", "manual recovery force", "fault log and restart state"], "passCriteria": ["Safe motion limits set by risk assessment before test", "No automatic restart after power restoration", "Contradictory end/lock states inhibit enable", "Any tracking error beyond E2 target inhibits further powered cycling"], "disconfirmingResult": "A single blocked guide racks the roof, releases a pin or cannot be safely recovered.", "status": "Not run" }, { "id": "E4-cycling", "name": "Dry and contaminated repeatability", "method": "500 initial guarded dry cycles, inspect, then a separately defined measured dust exposure and further 500 screening cycles. Record debris dose/type and cleaning, not an undefined 'desert-proof' claim.", "measurements": ["torque drift", "backlash", "angle tracking", "bushing/skin wear", "cleaning time"], "passCriteria": ["Continue to meet E1–E3 criteria", "Proposed stop threshold: more than 20% rise in unloaded drive force after identical cleaning", "No cracks, loose retainers, tooth damage or unintended contact"], "disconfirmingResult": "A clean-lab mechanism becomes unreliable with practical service contamination.", "status": "Not run" }, { "id": "E5-rain", "name": "Four-valley collection and disconnect sequencing", "method": "Only on locked rig, install all drains. Supply measured rainfall including 10 mm/h equivalent, dirty first-flush challenge and one blocked gutter. Weigh feed, first flush, buffer, overflow and losses.", "measurements": ["mass balance closure", "collection fraction", "ponding depth", "overflow route", "residual drain water"], "passCriteria": ["Proposed mass-balance screening within ±5% of input", "No unintended water retention or wet electrical path", "Connected drain state inhibits unlocking; manually verify actual removal", "Water remains labeled nonpotable"], "disconfirmingResult": "Water ponds between leaves, bypasses intended gutters, enters electrical service or remains trapped after draining.", "status": "Not run" }, { "id": "E6-breathing-skin", "name": "Laminate pressure-angle / strain / energy coupon", "method": "Screen small material coupons before full-size integration. After material/fixture review, use guarded low-pressure steps, independent relief and vent; initial commissioning ceiling proposed at 20 kPa gauge, not a material rating. Increase only after review of measured deformation and fixture limits.", "measurements": ["pressure-angle curve", "local curvature/strain markers", "hysteresis", "leak-down", "electrical energy per cycle and hold", "permanent set", "PV island strain"], "passCriteria": ["Repeatable direction and useful stroke with no crack/delamination", "Vent and pressure loss return to a defined tested safe state", "Proposed 10000-cycle screening after initial material validation; not a lifetime guarantee", "Stop on growing leak, hysteresis, residual set or visible damage"], "disconfirmingResult": "Laminate needs unsafe pressure, loses useful stroke, damages PV, leaks excessively or consumes more energy than its environmental benefit.", "status": "Not run" }, { "id": "E7-repair-dock", "name": "Human-first replaceable skin and service interface", "method": "Time removal/reinstallation after DC isolation, venting and applicable draining. Deliberately attempt wrong orientation and wrong wet/dry mate with inert test connectors; cycle locating and retention geometry.", "measurements": ["replacement time", "assembly force", "play", "retention proof", "wrong-way mate result", "interface leakage/insulation after service"], "passCriteria": ["Wrong-way mechanical insertion rejected by geometry", "Wet and electrical couplings cannot be mistaken for each other", "Separate retainer is required and engagement is inspectable", "No need to unlock or disturb supported canopy for cassette replacement"], "disconfirmingResult": "Universal-looking geometry permits wrong-service connection or hides an unretained slide-out state.", "status": "Not run" } ], "advancedDemonstrators": [ {"id": "A1-zipper-tube", "objective": "Compact service gantry with high off-axis stiffness", "method": "Reproduce source geometry first in thin sheet, compare matched-mass single and coupled zipper tubes; thicken only after closure verification.", "proposedProof": "At least 2× repeatable mass-normalized bending stiffness against matched baseline while retaining full deployment; separately restrain deployment mode.", "evidence": ["O02", "O03", "O18"], "status": "Planned, not built"}, {"id": "A2-snap-lock-vent", "objective": "Passive state barrier and dry geometry-controlled ventilation", "method": "Reproduce source-scale PETG snap-lock tube separately from a mixed-mode ventilation lattice. Measure barrier/reverse force and pressure-drop/open-area/dust response respectively.", "proposedProof": "Measured state separation survives repeated cycling; vent can be cleaned and retains predictable area/pressure drop. No load-column or filter claim.", "evidence": ["O04", "O05"], "status": "Planned, not built"}, {"id": "A3-kresling-dock", "objective": "Compact protective bellows / tactile preload at dry service dock", "method": "Use independent axial/twist fixture, compare shell to conventional spring/bellows at matched travel. Do not use as a pressure boundary.", "proposedProof": "Repeatable force-displacement and twist path, measured recovery and no drift that permits false docking state.", "evidence": ["O16"], "status": "Planned, not built"}, {"id": "A4-breathing-repair-skin", "objective": "Soft robotic PV/shade skin on durable repairable dock", "method": "Compare compliant coupon with geared rigid flap at equal shaded area; replace both via the same segregated service interface.", "proposedProof": "Measured energy/noise/repair/cycle tradeoffs justify the compliant option for at least one duty; interface works even if conventional actuator wins.", "evidence": ["O08", "O09", "O11", "O12"], "status": "Planned, not built"} ], "structuralBoundary": "Bench tests do not qualify a roof. Full-scale member/lock/receiver/rail/foundation analysis, asymmetric gust and uplift tests, site anchor tests, snow/ice/water accumulation assessment, fatigue, electrical and pressure safety review are separate mandatory gates before occupied use.", "evidenceBoundary": "Numerical geometry checks in validation.json validate the implemented mathematical model only. Every physical experiment remains explicitly Not run." }