Engineering topics
Publications and source records attributed to Rockey, D. E..
Algorithm developed for predicting power output, uniformity of intensity and operating temperature of concentrator-enhanced photovoltaic solar cell arrays. Optimum values for parameters such as reflector geometry found prior to constructing scale models for testing.
Concentrator uses off-axis geometry to achieve efficient uniform illumination of photovoltaic cells. Primary reflector is parabolic cylinder and therefore readily adaptable to rolling up for transport and unrolling for deployment. Foldable cylindrical structure has potiential for both terrestrial and space applications.
Photovoltaic and fission reactor orbital power systems are compared in terms of the end-to-end system power-to-mass ratios. Three PV systems are examined, i.e., a solid substrate with a cell array and a NiCd battery, a modified SEP array and an NiH2 battery, and a 62-micron Si cell array and a fuel cell. All arrays were modeled to be 13.5% efficient and to produce 25 kW dc. The SP-100 reactor consists of the heat source, radiation shield, heat pipes to transfer thermal energy from the reactor to thermoelectric elements, and a waste heat radiator. Consideration is given to system applications in orbits ranging from LEO to GEO, and to mission durations of 1, 5, and 10 yr. PV systems are concluded to be flight-proven, useful out of radiation belts, and best for low to moderate power levels. Limitations exist for operations where atmospheric drag may become a factor and due to the size of a large PV power supply. Space nuclear reactors will continue under development and uses at high power levels and in low altitude orbits are foreseen.
Specific design features to reduce cell mass, lower panel operating temperatures, and improve power to mass ratios for silicon solar cell arrays in space applications are presented. Because mass constraints limit payload capacity for launch into GEO, graphite/epoxy structures combined with high performance Si cells are needed to deliver a power/mass ratio of 265 W/kg, notably for Solar Electric Propulsion systems, compared with existing level of 65 W/kg. Shallow diffusion and back surface field cell technology have raised cell efficiencies to 15%, with a back emissivity of 1.64. Structural design requirements comprise Shuttle interface compatibility, full ground test capability, low mass, and high stiffness. Three array alternatives are discussed, and the STACBEAM configuration, which consists of a triangular truss and a piston deployer with folding accomplished on simple hinges, provides 0.2 Hz stiffness and achieves the design power/mass goals.
Results of a study are presented suggesting that a Galileo Jupiter orbiting mission could be performed with a concentrated solar array power source. A baseline spacecraft design using concentrated arrays is given, and the overall spacecraft implications for attitude control, propulsion, power conditioning and the resultant spacecraft mass are examined. It is noted that while the concentrated array concept still requires extensive development effort, no insurmountable system level barriers preclude the use of a concentrated solar array on this difficult mission, with its stressing radiation environment, its lengthy periods of spacecraft shadowing as it passes behind Jupiter, and, finally, its large delta v burn required for orbital insertion.
The useful operational range of photovoltaic solar arrays has been limited to 1.5 AU (Mars orbit) due primarily to solar intensity constraints. Preliminary results indicate that the use of concentrator mirrors in conjunction with solar arrays can extend the practical operating range of photovoltaic space power sources to at least 9.5 AU (Saturn orbit). Various aspects of concentrator-enhanced photovoltaic arrays such as size, structure, thermal characteristics, intensity uniformity, pointing accuracy requirements, deployment methods, power performance and system mass are presented. Based on this information, concentrator-enhanced photovoltaic arrays are superior, with respect to power-to-mass and cost, to existing power sources used for deep space missions. The sensitivity of concentrator-enhanced solar arrays to particulate radiation was also examined for representative deep space missions. Results are presented which show that a radiation-degraded, deep space, concentrator-enhanced solar array's performance exceeds that of existing RTG power sources.
The unique set of operating constraints determining key concentrating solar array design characteristics for low earth orbital, geosynchronous and interplanetary missions are considered. Minimum cost is crucial at low earth orbits, performance and design life are needed in geosynchronous orbit, and structural pointing accuracy and radiation resistance are essential in interplanetary designs. The impact of such emerging technologies as ultrathin cells, gallium arsenide cells and cold mirrors is discussed. Power-to-mass ratios as high as 200 W per kilogram at a distance of 1 astronomical unit from the sun are possible, using concentrators in conjunction with gallium arsenide arrays.
A general approach is developed for predicting the power output of a concentrator enhanced photovoltaic space array. A ray trace routine determines the concentrator intensity arriving at each solar cell. An iterative calculation determines the cell's operating temperature since cell temperature and cell efficiency are functions of one another. The end result of the iterative calculation is that the individual cell's power output is determined as a function of temperature and intensity. Circuit output is predicted by combining the individual cell outputs using the single diode model of a solar cell. Concentrated array characteristics such as uniformity of intensity and operating temperature at various points across the array are examined using computer modeling techniques. An illustrative example is given showing how the output of an array can be enhanced using solar concentration techniques.
This paper presents methods of incorporating ultrathin silicon solar cells into photovoltaic blankets for space applications. This type of cell has the highest power-to-mass ratio and best performance under space radiation of any silicon solar cell. Interconnect materials and designs, and the results of the investigation of the applicability of parallel-gap resistance welding for interconnecting ultrathin cells are discussed. Data relating contact pull strength and cell electrical degradation to welding parameters such as time, voltage, and pressure are presented. Methods for bonding ultrathin cells to flexible substrates and for bonding thin covers to these cells are described, and the results of vacuum thermal cycling and thermal soak tests on prototype ultrathin cell test coupons are included.