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At least 253 records · Page 14

Polycrystalline silicon study: Low-cost silicon refining technology prospects and semiconductor-grade polycrystalline silicon availability through 1988

Photovoltaic arrays that convert solar energy into electrical energy can become a cost effective bulk energy generation alternative, provided that an adequate supply of low cost materials is available. One of the key requirements for economic photovoltaic cells is reasonably priced silicon. At present, the photovoltaic industry is dependent upon polycrystalline silicon refined by the Siemens process primarily for integrated circuits, power devices, and discrete semiconductor devices. This dependency is expected to continue until the DOE sponsored low cost silicon refining technology developments have matured to the point where they are in commercial use. The photovoltaic industry can then develop its own source of supply. Silicon material availability and market pricing projections through 1988 are updated based on data collected early in 1984. The silicon refining industry plans to meet the increasing demands of the semiconductor device and photovoltaic product industries are overviewed. In addition, the DOE sponsored technology research for producing low cost polycrystalline silicon, probabilistic cost analysis for the two most promising production processes for achieving the DOE cost goals, and the impacts of the DOE photovoltaics program silicon refining research upon the commercial polycrystalline silicon refining industry are addressed.

Costogue, E. N.↗

Solar cells fabricated with unconventional silicon materials

Solar cells have been fabricated using silicon materials supplied in the DOE/JPL Large Solar Array program. Each of the silicon materials studied in this program was produced in a unique manner and with intent of producing silicon in a grade and form that would offer the possibility of economic deployment in photovoltaic arrays for generation of electricity. This report will attempt to provide an overview of the results for some of the materials and highlight in particular results obtained for solar cells fabricated from the advanced CZ silicon. Emphasis will be given to consideration of the purity of virgin silicon material used in the heat exchange method.

Minahan, J. A.↗

Experimental Charging Behavior of Orion UltraFlex Array Designs

The present ground based investigations give the first definitive look describing the charging behavior of Orion UltraFlex arrays in both the Low Earth Orbital (LEO) and geosynchronous (GEO) environments. Note the LEO charging environment also applies to the International Space Station (ISS). The GEO charging environment includes the bounding case for all lunar mission environments. The UltraFlex photovoltaic array technology is targeted to become the sole power system for life support and on-orbit power for the manned Orion Crew Exploration Vehicle (CEV). The purpose of the experimental tests is to gain an understanding of the complex charging behavior to answer some of the basic performance and survivability issues to ascertain if a single UltraFlex array design will be able to cope with the projected worst case LEO and GEO charging environments. Stage 1 LEO plasma testing revealed that all four arrays successfully passed arc threshold bias tests down to -240 V. Stage 2 GEO electron gun charging tests revealed that only the front side area of indium tin oxide coated array designs successfully passed the arc frequency tests

Golofaro, Joel T.↗

Thin-Film Solar Cells on Metal Foil Substrates for Space Power

Photovoltaic arrays have played a key role in power generation in space. The current technology will continue to evolve but is limited in the important mass specific power metric (MSP or power/weight ratio) because it is based on bulk crystal technology. The objective of this research is to continue development of an innovative photovoltaic technology for satellite power sources that could provide up to an order of magnitude saving in both weight and cost, and is inherently radiation-tolerant through use of thin film technology and thin foil substrates such as 5-mil thick stainless steel foil or 1-mil thick Ti. Current single crystal technology for space power can cost more than $300 per watt at the array level and weigh more than 1 kg/sq m equivalent to specific power of approx. 65 W/kg. Thin film material such as CuIn(1-x),Ga(x)S2, (CIGS2), CuIn(1-x), G(x)Se(2-y),S(y), (CIGSS) or amorphous hydrogenated silicon (a-Si:H) may be able to reduce both the cost and mass per unit area by an order of magnitude. Manufacturing costs for solar arrays are an important consideration for total spacecraft budget. For a medium sized 5kW satellite, for example, the array manufacturing cost alone may exceed $2 million. Moving to thin film technology could reduce this expense to less than $500 K. Previous work at FSEC demonstrated the potential of achieving higher efficiencies from CIGSS thin film solar cells on 5-mil thick stainless steel foil as well as initial stages of facility augmentation for depositing thin film solar cells on larger (6"x 4") substrates. This paper presents further progress in processing on metal foil substrates. Also, previous work at DayStar demonstrated the feasibility of flexible-thin-film copper-indium-gallium-diselenide (CIGS) solar cells with a power-to-weight ratio in excess of 1000 W/kg. We will comment on progress on the critical issue of scale-up of the solar cell absorber deposition process. Several important technical issues need to be resolved to realize the benefits of lightweight technologies for solar arrays, such as: monolithic interconnects, lightweight array structures, and new ultra-light support and deployment mechanisms. Once the technology has gained spaceflight certification it should find rapid acceptance in specific satellite markets.

Raffaelle, Ryne P.↗

A Breakthrough Propulsion Architecture for Interstellar Precursor Missions: Phase I Final Report

Our breakthrough propulsion architecture is an innovative way to take advantage of kilometer-scale, multi-hundred megawatt, space-based, phased-array lasers to enable rapid transportation throughout the solar system. In this architecture, the laser would beam power over distances of up to 40 AU increasing the available power density relative to solar insolation by two orders of magnitude. The receiving vehicle would have a photovoltaic array with cells tuned to the laser frequency that outputs a voltage of 6 kV to directly-drive a lithium-fueled gridded ion thruster system at an ultra-high specific impulse of 40,000 s. Such a system could enable final spacecraft speeds of greater than 40 AU/year, potentially enabling missions to the solar gravity lens focus at 550 AU in less than 15 years. This is the propulsion architecture of the 22nd century.

Brophy, John↗

Atomic oxygen degradation of Intelsat 4-type solar array interconnects: Laboratory investigations

A Hughes 506 type communication satellite belonging to the Intelsat organization was marooned in low Earth orbit on March 14, 1990, following failure of the Titan third stage to separate properly. The satellite, Intelsat VI, was designed for service in geosynchronous orbit and contains several material configurations which are susceptible to attack by atomic oxygen. Analysis showed the silver foil interconnects in the satellite photovoltaic array to be the key materials issue because the silver is exposed directly to the atomic oxygen ram flux. The results are reported of atomic oxygen degradation testing of Intelsat VI type silver foil interconnects both as virgin material and in a configured solar cell element. Test results indicate that more than 80 pct. of the original thickness of silver in the Intelsat VI solar array interconnects should remain after completion of the proposed Space Shuttle rescue and/or reboost mission.

Koontz, S. L.↗

The potential impact of new power system technology on the design of a manned space station

Larger, more complex spacecraft of the future such as a manned Space Station will require electric power systems of 100 kW and more, orders of magnitude greater than the present state of the art. Power systems at this level will have a significant impact on the spacecraft design. Historically, long-lived spacecraft have relied on silicon solar cell arrays, a nickel-cadmium storage battery and operation at 28 V dc. These technologies lead to large array areas and heavy batteries for a Space Station application. This, in turn, presents orbit altitude maintenance, attitude control, energy management and launch weight and volume constraints. Size (area) and weight of such a power system can be reduced if new higher efficiency conversion and lighter weight storage technologies are used. Several promising technology options including concentrator solar photovoltaic arrays, solar thermal dynamic and ultimately nuclear dynamic systems to reduce area are discussed. Also, higher energy storage systems such as nickel-hydrogen and the regenerative fuel cell (RFC) and higher voltage power distribution which add system flexibility, simplicity and reduce weight are examined. Emphasis is placed on the attributes and development status of emerging technologies that are sufficiently developed so that they could be available for flight use in the early to mid 1990's.

Fordyce, J. S.↗

The potential impact of new power system technology on the design of a manned Space Station

Larger, more complex spacecraft of the future such as a manned Space Station will require electric power systems of 100 kW and more, orders of magnitude greater than the present state of the art. Power systems at this level will have a significant impact on the spacecraft design. Historically, long-lived spacecraft have relied on silicon solar cell arrays, a nickel-cadmium storage battery and operation at 28 V dc. These technologies lead to large array areas and heavy batteries for a Space Station application. This, in turn, presents orbit altitude maintenance, attitude control, energy management and launch weight and volume constraints. Size (area) and weight of such a power system can be reduced if new higher efficiency conversion and lighter weight storage technologies are used. Several promising technology options including concentrator solar photovoltaic arrays, solar thermal dynamic and ultimately nuclear dynamic systems to reduce area are discussed. Also, higher energy storage systems such as nickel-hydrogen and the regenerative fuel cell (RFC) and higher voltage power distribution which add system flexibility, simplicity and reduce weight are examined. Emphasis placed on the attributes and development status of emerging technologies that are sufficiently developed so that they could be available for flight use in the early to mid 1990's.

Fordyce, J. S.↗

Experimental Tests of UltraFlex Array Designs in Low Earth Orbital and Geosynchronous Charging Environments

The present ground based investigations give the first definitive look describing the expected on-orbit charging behavior of Orion UltraFlex array coupons in the Low Earth Orbital and Geosynchronous Environments. Furthermore, it is important to note that the LEO charging environment also applies to the International Space Station as well as to the lunar mission charging environments. The GEO charging environment includes the bounding case for all lunar orbital and lunar surface mission environments. The UltraFlex thin film photovoltaic array technology has been targeted to become the sole power system for life support and on-orbit power for the manned Aires Crew Exploration Vehicle. It is therefore, crucial to gain an understanding of the complex charging behavior to answer some of the basic performance and survivability issues in an attempt to ascertain that a single UltraFlex array design will be able to cope with the projected worst case LEO and GEO charging environments. Testing was limited to four array coupons, two coupons each from two different array manufactures, Emcore and Spectrolab. The layout of each array design is identical and varies only in the actual cell technology used. The individual array cells from each manufacturer have an antireflection layered coating and come in two different varieties either uncoated (only AR coating) or coated with a thin conducting ITO layer. The LEO Plasma tests revealed that all four coupons passed the arc threshold -120 V bias tests. GEO electron gun charging tests revealed that only front side area of ITO coated coupons passed tests. Only the Emcore AR array passed backside Stage 2 GEO Tests.

Galofaro, Joel T.↗

Photovoltaic power options for Mars

The performance of a photovoltaic array is considered in terms of the properties of the Martian surface. Attention is given to the low solar intensity and high temperatures of Mars and to the performance of different chemical structures for the cells such as GaAs and silicon cells. A sample case is examined and it is shown that certain variables are still not understood with respect to photovoltaic performance on other planets.

Landis, Geoffrey A.↗

A novel photovoltaic power system which uses a large area concentrator mirror

A preliminary analysis has been made of a novel photovoltaic power system concept. The system is composed of a small area, dense photovoltaic array, a large area solar concentrator, and a battery system for energy storage. The feasibility of such a system is assessed for space power applications. The orbital efficiency, specific power, mass, and area of the system are calculated under various conditions and compared with those for the organic Rankine cycle solar dynamic system proposed for Space Station. Near term and advanced large area concentrator photovoltaic systems not only compare favorably to solar dynamic systems in terms of performance but offer other benefits as well.

Arrison, Anne↗

The Abacus/Reflector and Integrated Symmetrical Concentrator: Concepts for Space Solar Power Collection and Transmission

New energy sources are vital for the development of emerging nations, and the growth of industry in developed economies. Also vital is the need for these energy sources to be clean and renewable. For the past several years, NASA has been taking a new look at collecting solar energy in space and transmitting it to Earth, to planetary surfaces, and to orbiting spacecraft. Several innovative concepts are being studied for the space segment component of solar power beaming. One is the Abacus/Reflector, a large sun-oriented array structure fixed to the transmitter, and a rotating RF reflector that tracks a receiving rectenna on Earth. This concept eliminates the need for power-conducting slip rings in rotating joints between the solar collectors and the transmitter. Another concept is the Integrated Symmetrical Concentrator (ISC), composed of two very large segmented reflectors which rotate to collect and reflect the incident sunlight onto two centrally-located photovoltaic arrays. Adjacent to the PV arrays is the RF transmitter, which as a unit track the receiving rectenna, again eliminating power-conducting joints, and in addition reducing the cable lengths between the arrays and transmitter. The metering structure to maintain the position of the reflectors is a long mast, oriented perpendicular to the equatorial orbit plane. This paper presents a status of ongoing systems studies and configurations for the Abacus/Reflector and the ISC concepts, and a top-level study of packaging for launch and assembly.

Carrington, Connie↗

Evaluation of Kapton pyrolysis, arc tracking, and arc propagation on the Space Station Freedom (SSF) solar array Flexible Current Carrier (FCC)

Recent studies involving the use of polyimide Kapton coated wires indicate that if a momentary electrical short circuit occurs between two wires, sufficient heating of the Kapton can occur to thermally char (pyrolyze) the Kapton. Such charred Kapton has sufficient electrical conductivity to create an arc which tracks down the wires and possibly propagates to adjoining wires. These studies prompted an investigation to ascertain the likelihood of the Kapton pyrolysis, arc tracking and propagation phenomena, and the magnitude of destruction conceivably inflicted on Space Station Freedom's (SSF) Flexible Current Carrier (FCC) for the photovoltaic array. The geometric layout of the FCC, having a planar-type orientation as opposed to bundles, may reduce the probability of sustaining an arc. An experimental investigation was conducted to simulate conditions under which an arc can occur on the FCC of SSF, and the consequences of arc initiation.

Stueber, Thomas J.↗

Evaluation of Kapton pyrolysis, arc tracking, and arc propagation on the Space Station Freedom (SSF) solar array flexible current carrier (FCC)

Recent studies involving the use of polyimide Kapton coated wires indicate that if a momentary electrical short circuit occurs between two wires, sufficient heating of the Kapton can occur to themally chlar (pyrolyze) the Kapton. Such charred Kapton has sufficient electricxl conductivity to create an arc which tracks down the wires and possibly propagates to adjoining wires. These studies prompted an invetigation to ascertain the likelihood of Kapton pyrolysis, arc tracking and propagation phenomena, and the magnitude of destruction conceivably inflicted on Space Station Freedom's (SSF's) Flexible Current Carrier (FCC) for the photovoltaic array. The geometric layout of the FCC, having a planar-type orientation as opposed to bundles, may reduce the probability of sustaining an arc. An experimental investigation was conducted to simulate conditions under which an arc can occur on the FCC of the SSF, and the consequences of arc initiation.

Stueber, Thomas J.↗

PV Array Driven Adjustable Speed Drive for a Lunar Base Heat Pump

A study of various aspects of Adjustable Speed Drives (ASD) is presented. A summary of the relative merits of different ASD systems presently in vogue is discussed. The advantages of using microcomputer based ASDs is now widely understood and accepted. Of the three most popular drive systems, namely the Induction Motor Drive, Switched Reluctance Motor Drive and Brushless DC Motor Drive, any one may be chosen. The choice would depend on the nature of the application and its requirements. The suitability of the above mentioned drive systems for a photovoltaic array driven ASD for an aerospace application are discussed. The discussion is based on the experience of the authors, various researchers and industry. In chapter 2 a PV array power supply scheme has been proposed, this scheme will have an enhanced reliability in addition to the other known advantages of the case where a stand alone PV array is feeding the heat pump. In chapter 3 the results of computer simulation of PV array driven induction motor drive system have been included. A discussion on these preliminary simulation results have also been included in this chapter. Chapter 4 includes a brief discussion on various control techniques for three phase induction motors. A discussion on different power devices and their various performance characteristics is given in Chapter 5.

Domijan, Alexander, Jr.↗

Lunar Polar Exploration with Beamed Powered Rovers

Use of a laser to transmit power to a photovoltaic array has been proposed many times, including significant work done at NASA Glenn during the 1990s, but until recently the technology has lagged behind the ambitious requirements. The current NASA objective of lunar polar exploration provides the need, and evolution of higher-power and more efficient lasers provides the opportunity. Exploration of the ice-bearing craters near the lunar poles, where complete absence of sunlight precludes solar power, have been identified as a significant technology challenge for NASA’s future exploration. An approach to solve this is to use a laser to send power from the illuminated crater rim to a photovoltaic receiver on a rover inside the permanently dark region. A conceptual design was done of a prototype laser power system to be included on a proposed flight demonstration of the Kilopower space reactor. For the design, the laser transmitter is mounted on a small rover capable of moving to a location in line of sight of the receiving rover, e.g., on a crater rim with a view into the permanently dark region to be explored. A 250-watt laser diode bar transmits power at 808 nm, using a 10.5 cm optical beam director. The beam is received by a GaAs solar array mounted on the exploring rover, where it is converted into electrical power at ~50% optical to electrical efficiency. For the flight demonstration, 50 meters of laser transmission was required. The design showed a total laser mass of 7.8 kg is capable of producing the beam needed, not including the thermal control system. The demonstration design demonstrates 50-m transmission, but it would be valuable to have longer point-to-point beaming on the moon. Long beam paths require higher coherence than the diode laser bars of the demonstration system. The development of high-efficiency diode-pumped fiber lasers meets this technology need: and diode-pumped fiber lasers using the Er/Yb system can be purchased commercially with overall conversion efficiency of greater than 50% at wavelength 1.06 micrometers. Two technologies for a photovoltaic converter for this wavelength are the InGaAs photovoltaic cell, using technology developed for multi-junction space solar cells, or newly-developed high-quantum efficiency silicon cells. The next step to mature the technology would be a lunar flight demonstration. In the future, this has the potential to enhance and enable future human exploration of the moon, harvesting and utilizing the ice resources of these permanently-shadowed craters.

Geoffrey A Landis↗

PASP: A high voltage array experiment

In the near future, Air Force mission payloads will require significant increases in power. Sophisticated sensing systems such as infrared focal plane detector arrays and radar will be employed by the Air Force to fulfill its strategic objectives. These payloads will demand that the power subsystem provide up to 50 kW at the end of mission life, more than an order of magnitude greater than is currently required. Some of these payloads must be flown in low-Earth polar orbits to satisfy mission objectives, and it is likely that large (500 to 600 sq m) solar photovoltaic arrays will operate in the low-Earth polar environment. The standard 28 volt power subsystem is not weight efficient for the array power levels being considered. The impact of the solar array operating voltage on the total weight of the array and the subsystem power conditioning and distribution components is illustrated. In the interest of reducing power subsystem weight, higher array operating voltages are considered. The problems which the higher array voltage present to the array designer are discussed. In order to provide a maximum return on the tremendous investment of resources required to develop and place these assets in orbit, they must be designed to operate effectively for extended periods of time. To achieve this, the system must be able to function in the threat-induced and natural space environment.

Scott-Monck, J.↗

Pulsed laser illumination of photovoltaic cells

In future space missions, free electron lasers (FEL) may be used to illuminate photovoltaic array receivers to provide remote power. Both the radio-frequency (RF) and induction FEL provide FEL produce pulsed rather than continuous output. In this work we investigate cell response to pulsed laser light which simulates the RF FEL format. The results indicate that if the pulse repetition is high, cell efficiencies are only slightly reduced compared to constant illumination at the same wavelength. The frequency response of the cells is weak, with both voltage and current outputs essentially dc in nature. Comparison with previous experiments indicates that the RF FEL pulse format yields more efficient photovoltaic conversion than does an induction FEL pulse format.

Yater, Jane A.↗