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NASA NTRS1989

Estimated performance and future potential of solar dynamic and photovoltaic power systems for selected LEO and HEO missions

Solar Photo Voltaic (PV) and thermal dynamic power systems for application to selected Low Earth Orbit (LEO) and High Eccentric Orbit (Energy) (HEO) missions are characterized in the regime 7 to 35 kWe. Input parameters to the characterization are varied corresponding to anticipated introduction of improved or new technologies. Comparative assessment is made between the two power system types utilizing newly emerging technologies in cells and arrays, energy storage, optical surfaces, heat engines, thermal energy storage, and thermal management. The assessment is made to common ground rules and assumptions. The four missions (space station, sun-synchronous, Van Allen belt and GEO) are representative of the anticipated range of multi-kWe earth orbit missions. System characterizations include all required subsystems, including power conditioning, cabling, structure, to deliver electrical power to the user. Performance is estimated on the basis of three different levels of component technology: (1) state-of-art, (2) near-term, and (3) advanced technologies. These range from planar array silicon/IPV nickel hydrogen batteries and Brayton systems at 1000 K to thin film GaAs with high energy density secondary batteries or regenerative fuel cells and 1300 K Stirling systems with ultra-lightweight concentrators and radiators. The system estimates include design margin for performance degradations from the known environmental mechanisms (micrometeoroids and space debris, atomic oxygen, electron and proton flux) which are modeled and applied depending on the mission. The results give expected performance, mass and drag of multi-kWe earth orbiting solar power systems and show how overall system figures of merit will improve as new component technologies are incorporated.

Bents, David J.↗

NASA NTRS1999

Solar Power System Analyses for Electric Propulsion Missions

Solar electric propulsion (SEP) mission architectures are applicable to a wide range of NASA missions including human Mars exploration and robotic exploration of the outer planets. In this paper, we discuss the conceptual design and detailed performance analysis of an SEP stage electric power system (EPS). EPS performance, mass and area predictions are compared for several PV array technologies. Based on these studies, an EPS design for a 1-MW class, Human Mars Mission SEP stage was developed with a reasonable mass, 9.4 metric tons, and feasible deployed array area, 5800 sq m. An EPS was also designed for the Europa Mapper spacecraft and had a mass of 151 kg and a deployed array area of 106 sq m.

Kerslake, Thomas W.↗

NASA NTRS1985

Operational performance of the photovoltaic-powered grain mill and water pump at Tangaye, Burkina Faso (formerly Upper Volta)

A photovoltaic (PV) system powering a grain mill and water pump was installed in the remote African village of Tangaye, Burkina Faso (formerly Upper Volta) under the sponsorship of the U.S. Agency for International Development (AID) and by the National Aeronautics and Space Administration (NASA) Lewis Research Center (LeRC) in early 1979. The presence reports covers the second two years of operation from April 1981 through June 1983. During this time, the grain mill and water pump were operational 96 and 88 percent of the time respectively, and the PV system generated sufficient electricity to enable the grinding of about 111 metric tons of finely ground flow and the pumping of over 5000 cm sq of water from the 10 m deep well. The report includes a description of the current configuration of the system, a review of system performance, a discussion of the socioeconomic impact of the system on the villagers and a summary of results and conclusions covering the entire four-year period.

Martz, J. E.↗

NASA NTRS1989

Protoflight photovoltaic power module system-level tests in the space power facility

Work Package Four, which includes the NASA-Lewis and Rocketdyne, has selected an approach for the Space Station Freedom Photovoltaic (PV) Power Module flight certification that combines system level qualification and acceptance testing in the thermal vacuum environment: The protoflight vehicle approach. This approach maximizes ground test verification to assure system level performance and to minimize risk of on-orbit failures. The preliminary plans for system level thermal vacuum environmental testing of the protoflight PV Power Module in the NASA-Lewis Space Power Facility (SPF), are addressed. Details of the facility modifications to refurbish SPF, after 13 years of downtime, are briefly discussed. The results of an evaluation of the effectiveness of system level environmental testing in screening out incipient part and workmanship defects and unique failure modes are discussed. Preliminary test objectives, test hardware configurations, test support equipment, and operations are presented.

Rivera, Juan C.↗

NASA NTRS1989

Protoflight photovoltaic power module system-level tests in the Space Power Facility

Work Package Four, which includes the NASA-Lewis and Rocketdyne, has selected an approach for the Space Station Freedom Photovoltaic (PV) Power Module flight certification that combines system level qualification and acceptance testing in the thermal vacuum environment: the 'protoflight' vehicle approach. This approach maximizes ground test verification to assure system level performance and to minimize risk of on-orbit failures. The preliminary plans for system level thermal vacuum environmental testing of the protoflight PV Power Module in the NASA-Lewis Space Power Facility (SPF) are addressed. Details of the facility modifications to refurbish SPF, after 13 years of downtime, are briefly discussed. The results of an evaluation of the effectiveness of system level environmental testing in screening out incipient part and workmanship defects and unique failure modes are discussed. Preliminary test objectives, test hardware configurations, test support equipment, and operations, are presented.

Rivera, Juan C.↗

NASA NTRS1986

Flat-plate solar array project. Volume 7: Module encapsulation

The objective of the Encapsulation Task was to develop, demonstrate, and qualify photovoltaic (PV) module encapsulation systems that would provide 20 year (later decreased to 30 year) life expectancies in terrestrial environments, and which would be compatible with the cost and performance goals of the Flat-Plate Solar Array (FSA) Project. The scope of the Encapsulation Task included the identification, development, and evaluation of material systems and configurations required to support and protect the optically and electrically active solar cell circuit components in the PV module operating environment. Encapsulation material technologies summarized include the development of low cost ultraviolet protection techniques, stable low cost pottants, soiling resistant coatings, electrical isolation criteria, processes for optimum interface bonding, and analytical and experimental tools for evaluating the long term durability and structural adequacy of encapsulated modules. Field testing, accelerated stress testing, and design studies have demonstrated that encapsulation materials, processes, and configurations are available that meet the FSA cost and performance goals.

Cuddihy, E.↗

NASA NTRS1990

Space Station Freedom electric power system availability study

The results are detailed of follow-on availability analyses performed on the Space Station Freedom electric power system (EPS). The scope includes analyses of several EPS design variations, these are: the 4-photovoltaic (PV) module baseline EPS design, a 6-PV module EPS design, and a 3-solar dynamic module EPS design which included a 10 kW PV module. The analyses performed included: determining the discrete power levels that the EPS will operate at upon various component failures and the availability of each of these operating states; ranking EPS components by the relative contribution each component type gives to the power availability of the EPS; determining the availability impacts of including structural and long-life EPS components in the availability models used in the analyses; determining optimum sparing strategies, for storing space EPS components on-orbit, to maintain high average-power-capability with low lift-mass requirements; and analyses to determine the sensitivity of EPS-availability to uncertainties in the component reliability and maintainability data used.

Turnquist, Scott R.↗

NASA NTRS2016

Multilayer Active Shell Mirrors for Space Telescopes

A novel active mirror technology based on carbon fiber reinforced polymer (CFRP) substrates and replication techniques has been developed. Multiple additional layers are implemented into the design serving various functions. Nanolaminate metal films are used to provide a high quality reflective front surface. A backing layer of thin active material is implemented to provide the surface-parallel actuation scheme. Printed electronics are used to create a custom electrode pattern and flexible routing layer. Mirrors of this design are thin (< 1.0 mm), lightweight (2.7 kg/m2 ), and have large actuation capabilities. These capabilities, along with the associated manufacturing processes, represent a significant change in design compared to traditional optics. Such mirrors could be used as lightweight primaries for small CubeSat-based telescopes or as meter-class segments for future large aperture observatories. Multiple mirrors can be produced under identical conditions enabling a substantial reduction in manufacturing cost and complexity. An overview of the mirror design and manufacturing processes is presented. Predictions on the actuation performance have been made through finite element simulations demonstrating correct abilities on the order of 250−300× for astigmatic modes with only 41 independent actuators. A description of the custom metrology system used to characterize the active mirrors is also presented. The system is based on a Reverse Hartmann test and can accommodate extremely large deviations in mirror figure (> 100 µm PV) down to sub-micron precision. The system has been validated against several traditional techniques including photogrammetry and interferometry. The mirror performance has been characterized using this system, as well as closed-loop figure correction experiments on 150 mm dia. prototypes. The mirrors have demonstrated post-correction figure accuracies of 200 nm RMS (two dead actuators limiting performance).

Reverse Hartmann↗

NASA NTRS1982

Research possibilities? No! Needs for research to make PV solar energy utilization broadly competitive

The historical progression of efficiency improvements, cost reductions, and performance improvements in modules and photovoltaic systems are described. The potential for future improvements in photovoltaic device efficiencies and cost reductions continues as device concepts, designs, processes, and automated production capabilities mature. Additional step-function improvements can be made as today's simpler devices are replaced by more sophisticated devices.

Wolf, M.↗

NASA NTRS1991

Effects of Martian dust on power system components

Before large power systems for manned exploration of the Martian surface can be put into place, it must be determined how their performance will be affected by the Martian environment. A program was started to assess the impact of these environmental factors on power system performance, and to find ways to mitigate the degradative effects. The effects of blowing dust on photovoltaic (PV) and radiator surfaces is studied. Extensive use was made of the Martian Surface Wind Tunnel (MARSWIT) located at NASA-Ames to simulate Martian winds. Two basic types of experiment sets were run. In the first, the threshold clearing velocity of dust deposited on PV coverslip material and high emissivity radiator materials in clear Martian-like winds was examined. In the second, dust was dropped near the inlet of the wind tunnel and the winds were allowed to carry the dust past the samples, simulating a dust storm. A summary of results is given.

Gaier, J. R.↗

NASA NTRS2009

Development and Testing of the Glenn Research Center Visitor's Center Grid-Tied Photovoltaic Power System

The NASA Glenn Research Center (GRC) has developed, installed, and tested a 12 kW DC grid-tied photovoltaic (PV) power system at the GRC Visitor s Center. This system utilizes a unique ballast type roof mount for installing the photovoltaic panels on the roof of the Visitor s Center with no alterations or penetrations to the roof. The PV system has generated in excess of 15000 kWh since operation commenced in August 2008. The PV system is providing power to the GRC grid for use by all. Operation of the GRC Visitor s Center PV system has been completely trouble free. A grid-tied PV power system is connected directly to the utility distribution grid. Facility power can be obtained from the utility system as normal. The PV system is synchronized with the utility system to provide power for the facility, and excess power is provided to the utility. The project transfers space technology to terrestrial use via nontraditional partners. GRC personnel glean valuable experience with PV power systems that are directly applicable to various space power systems, and provides valuable space program test data. PV power systems help to reduce harmful emissions and reduce the Nation s dependence on fossil fuels. Power generated by the PV system reduces the GRC utility demand, and the surplus power aids the community. Present global energy concerns reinforce the need for the development of alternative energy systems. Modern PV panels are readily available, reliable, efficient, and economical with a life expectancy of at least 25 years. Modern electronics has been the enabling technology behind grid-tied power systems, making them safe, reliable, efficient, and economical with a life expectancy of at least 25 years. Based upon the success of the GRC Visitor s Center PV system, additional PV power system expansion at GRC is under consideration. The GRC Visitor s Center grid-tied PV power system was successfully designed and developed which served to validate the basic principles described, and the theoretical work that was performed. The report concludes that grid-tied photovoltaic power systems are reliable, maintenance free, long life power systems, and are of significant value to NASA and the community.

Eichenberg, Dennis J.↗

NASA NTRS2009

Development and Testing of a Prototype Grid-Tied Photovoltaic Power System

The NASA Glenn Research Center (GRC) has developed and tested a prototype 2 kW DC grid-tied photovoltaic (PV) power system at the Center. The PV system has generated in excess of 6700 kWh since operation commenced in July 2006. The PV system is providing power to the GRC grid for use by all. Operation of the prototype PV system has been completely trouble free. A grid-tied PV power system is connected directly to the utility distribution grid. Facility power can be obtained from the utility system as normal. The PV system is synchronized with the utility system to provide power for the facility, and excess power is provided to the utility. The project transfers space technology to terrestrial use via nontraditional partners. GRC personnel glean valuable experience with PV power systems that are directly applicable to various space power systems, and provide valuable space program test data. PV power systems help to reduce harmful emissions and reduce the Nation s dependence on fossil fuels. Power generated by the PV system reduces the GRC utility demand, and the surplus power aids the community. Present global energy concerns reinforce the need for the development of alternative energy systems. Modern PV panels are readily available, reliable, efficient, and economical with a life expectancy of at least 25 years. Modern electronics has been the enabling technology behind grid-tied power systems, making them safe, reliable, efficient, and economical with a life expectancy of at least 25 years. Based upon the success of the prototype PV system, additional PV power system expansion at GRC is under consideration. The prototype grid-tied PV power system was successfully designed and developed which served to validate the basic principles described, and the theoretical work that was performed. The report concludes that grid-tied photovoltaic power systems are reliable, maintenance free, long life power systems, and are of significant value to NASA and the community.

Eichenberg, Dennis J.↗

NASA NTRS2003

The Implementation of Advanced Solar Array Technology in Future NASA Missions

Advanced solar array technology is expected to be critical in achieving the mission goals on many future NASA space flight programs. Current PV cell development programs offer significant potential and performance improvements. However, in order to achieve the performance improvements promised by these devices, new solar array structures must be designed and developed to accommodate these new PV cell technologies. This paper will address the use of advanced solar array technology in future NASA space missions and specifically look at how newer solar cell technologies impact solar array designs and overall power system performance.

Piszczor, Michael F.↗

NASA NTRS1989

Magnification of starting torques of dc motors by maximum power point trackers in photovoltaic systems

Direct current (dc) motors are used in terrestrial photovoltaic (PV) systems such as in water-pumping systems for irrigation and water supply. Direct current motors may also be used for space applications. Simple and low weight systems including dc motors may be of special interest in space where the motors are directly coupled to the solar cell array (with no storage). The system will operate only during times when sufficient insolation is available. An important performance characteristic of electric motors is the starting to rated torque ratio. Different types of dc motors have different starting torque ratios. These ratios are dictated by the size of solar cell array, and the developed motor torque may not be sufficient to overcome the load starting torque. By including a maximum power point tracker (MPPT) in the PV system, the starting to rated torque ratio will increase, the amount of which depends on the motor type. The starting torque ratio is calculated for the permanent magnet, series and shunt excited dc motors when powered by solar cell arrays for two cases: with and without MPPT's. Defining a motor torque magnification by the ratio of the motor torque with an MPPT to the motor torque without an MPPT, a magnification of 3 was obtained for the permanent magnet motor and a magnification of 7 for both the series and shunt motors. The effect of the variation of solar insolation on the motor starting torque was covered. All motor types are less sensitive to insolation variation in systems including MPPT's as compared to systems with MPPT's. The analysis of this paper will assist the PV system designed to determine whether or not to include an MPPT in the system for a specific motor type.

Appelbaum, Joseph↗

NASA NTRS1982

Operational performance of the photovoltaic-powered grain mill and water pump at Tangaye, Upper Volta

The first two years of operation of a stand alone photovoltaic (PV) power system for the village of Tangaye, Upper Volta in West Africa are described. The purpose of the experiment was to demonstrate that PV systems could provide reliable electrical power for multiple use applications in remote areas where local technical expertise is limited. The 1.8 kW (peak) power system supplies 120-V (d.c.) electrical power to operate a grain mill, a water pump, and mill building lights for the village. The system was initially sized to pump a part of the village water requirements from an existing improved well, and to meet a portion of the village grain grinding requirements. The data, observations, experiences, and conclusions developed during the first two years of operation are discussed. Reports of tests of the mills used in the project are included.

Martz, J. E.↗

NASA NTRS2006

Modular, Reconfigurable, High-Energy Technology Development

The Modular, Reconfigurable High-Energy (MRHE) Technology Demonstrator project was to have been a series of ground-based demonstrations to mature critical technologies needed for in-space assembly of a highpower high-voltage modular spacecraft in low Earth orbit, enabling the development of future modular solar-powered exploration cargo-transport vehicles and infrastructure. MRHE was a project in the High Energy Space Systems (HESS) Program, within NASA's Exploration Systems Research and Technology (ESR&T) Program. NASA participants included Marshall Space Flight Center (MSFC), the Jet Propulsion Laboratory (JPL), and Glenn Research Center (GRC). Contractor participants were the Boeing Phantom Works in Huntsville, AL, Lockheed Martin Advanced Technology Center in Palo Alto, CA, ENTECH, Inc. in Keller, TX, and the University of AL Huntsville (UAH). MRHE's technical objectives were to mature: (a) lightweight, efficient, high-voltage, radiation-resistant solar power generation (SPG) technologies; (b) innovative, lightweight, efficient thermal management systems; (c) efficient, 100kW-class, high-voltage power delivery systems from an SPG to an electric thruster system; (d) autonomous rendezvous and docking technology for in-space assembly of modular, reconfigurable spacecraft; (e) robotic assembly of modular space systems; and (f) modular, reconfigurable distributed avionics technologies. Maturation of these technologies was to be implemented through a series of increasingly-inclusive laboratory demonstrations that would have integrated and demonstrated two systems-of-systems: (a) the autonomous rendezvous and docking of modular spacecraft with deployable structures, robotic assembly, reconfiguration both during assembly and (b) the development and integration of an advanced thermal heat pipe and a high-voltage power delivery system with a representative lightweight high-voltage SPG array. In addition, an integrated simulation testbed would have been developed containing software models representing the technologies being matured in the laboratory demos. The testbed would have also included models for non-MRHE developed subsystems such as electric propulsion, so that end-to-end performance could have been assessed. This paper presents an overview of the MRHE Phase I activities at MSFC and its contractor partners. One of the major Phase I accomplishments is the assembly demonstration in the Lockheed Martin Advanced Technology Center (LMATC) Robot-Satellite facility, in which three robot-satellites successfully demonstrated rendezvous & docking, self-assembly, reconfiguration, adaptable GN&C, deployment, and interfaces between modules. Phase I technology maturation results from ENTECH include material recommendations for radiation hardened Stretched Lens Array (SLA) concentrator lenses, and a design concept and test results for a hi-voltage PV receiver. UAH's accomplishments include Supertube heatpipe test results, which support estimates of thermal conductivities at 30,000 times that of an equivalent silver rod. MSFC performed systems trades and developed a preliminary concept design for a 100kW-class modular reconfigurable solar electric propulsion transport vehicle, and Boeing Phantom Works in Huntsville performed assembly and rendezvous and docking trades. A concept animation video was produced by SAIC, wllich showed rendezvous and docking and SLA-square-rigger deployment in LEO.

Carrington, Connie↗

NASA NTRS2015

Space Environment Testing of Photovoltaic Array Systems at NASA's Marshall Space Flight Center

To successfully operate a photovoltaic (PV) array system in space requires planning and testing to account for the effects of the space environment. It is critical to understand space environment interactions not only on the PV components, but also the array substrate materials, wiring harnesses, connectors, and protection circuitry (e.g. blocking diodes). Key elements of the space environment which must be accounted for in a PV system design include: Solar Photon Radiation, Charged Particle Radiation, Plasma, and Thermal Cycling. While solar photon radiation is central to generating power in PV systems, the complete spectrum includes short wavelength ultraviolet components, which photo-ionize materials, as well as long wavelength infrared which heat materials. High energy electron radiation has been demonstrated to significantly reduce the output power of III-V type PV cells; and proton radiation damages material surfaces - often impacting coverglasses and antireflective coatings. Plasma environments influence electrostatic charging of PV array materials, and must be understood to ensure that long duration arcs do not form and potentially destroy PV cells. Thermal cycling impacts all components on a PV array by inducing stresses due to thermal expansion and contraction. Given such demanding environments, and the complexity of structures and materials that form a PV array system, mission success can only be ensured through realistic testing in the laboratory. NASA's Marshall Space Flight Center has developed a broad space environment test capability to allow PV array designers and manufacturers to verify their system's integrity and avoid costly on-orbit failures. The Marshall Space Flight Center test capabilities are available to government, commercial, and university customers. Test solutions are tailored to meet the customer's needs, and can include performance assessments, such as flash testing in the case of PV cells.

Phillips, Brandon S.↗

NASA NTRS1987

Overview of NASA Lewis Research Center free-piston Stirling engine technology activities applicable to space power systems

A brief overview is presented of the development and technological activities of the free-piston Stirling engine. The engine started as a small scale fractional horsepower engine which demonstrated basic engine operating principles and the advantages of being hermetically sealed, highly efficient, and simple. It eventually developed into the free piston Stirling engine driven heat pump, and then into the SP-100 Space Reactor Power Program from which came the Space Power Demonstrator Engine (SPDE). The SPDE successfully operated for over 300 hr and delivered 20 kW of PV power to an alternator plunger. The SPDE demonstrated that a dynamic power conversion system can, with proper design, be balanced; and the engine performed well with externally pumped hydrostatic gas bearings.

Slaby, Jack G.↗