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Phase II Objectives: Optimize Mega-ROSA/ROSA solar array materials and structures; Characterize creep/relaxation phenomena; Perform analytical modeling; Optimize the array's manufacturing process
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The requirements, the design, and the test program which were carried out in producing the Space Telescope Solar Array (STSA) primary deployment mechanisms (PDM) are described. The PDM will be used to rotate the rolled solar array supporting boom from its launch position alongside the telescope housing, through 90 deg to its use position. After five years in space the array is to be rerolled and by use of the PDM swung back to its stowed position alongside the telescope housing for capture and return to Earth via the Space Shuttle.
A roll-out flexible array which provides more than 4 kW of power for the space telescope was developed. The Array is configured as two wings. The deployment mechanism for each wing is based on flight-proven FRUSA design. Modifications have been incorporated to accommodate an increase in size and mission requirements. The assembly and operation of the deployment mechanism are described together with environmental and functional tests results.
The power generation capability of the International Space Station (ISS) is being augmented with the installation of new solar arrays. The new solar arrays, named iROSA (ISS Roll Out Solar Array), are installed in front of original main truss solar arrays and integrate into the existing structure and electrical power system of the ISS. However, iROSA represents significant changes in technology for solar arrays compared to the original solar arrays on the ISS main truss. Knowing the power capabilities of the augmented solar arrays is critical for near-term and long-term mission planning and utilization. This new iROSA installation thus requires updates to be made to the prior-day methods of calculating power generation capability for the ISS. New types of solar cells and array designs, both electrically and structurally, present challenges for concurrent computational modeling of both the original solar arrays and the newer iROSA. This presentation will detail the development and integration of the computational models to calculate the power for the augmented arrays on ISS and the evaluation of the model to ensure that it functions with and without iROSA and returns accurate predictions of power generation in nominal and off-nominal conditions.
The Flexible Array Concentrator Technology (FACT) is a lightweight, high-performance reflective concentrator blanket assembly that can be used on flexible solar array blankets. The FACT concentrator replaces every other row of solar cells on a solar array blanket, significantly reducing the cost of the array. The modular design is highly scalable for the array system designer, and exhibits compact stowage, good off-pointing acceptance, and mass/cost savings. The assembly s relatively low concentration ratio, accompanied by a large radiative area, provides for a low cell operating temperature, and eliminates many of the thermal problems inherent in high-concentration-ratio designs. Unlike other reflector technologies, the FACT concentrator modules function on both z-fold and rolled flexible solar array blankets, as well as rigid array systems. Mega-ROSA (Mega Roll-Out Solar Array) is a new, highly modularized and extremely scalable version of ROSA that provides immense power level range capability from 100 kW to several MW in size. Mega-ROSA will enable extremely high-power spacecraft and SEP-powered missions, including space-tug and largescale planetary science and lunar/asteroid exploration missions. Mega-ROSA's inherent broad power scalability is achieved while retaining ROSA s solar array performance metrics and missionenabling features for lightweight, compact stowage volume and affordability. This innovation will enable future ultra-high-power missions through lowcost (25 to 50% cost savings, depending on PV and blanket technology), lightweight, high specific power (greater than 200 to 400 Watts per kilogram BOL (beginning-of-life) at the wing level depending on PV and blanket technology), compact stowage volume (greater than 50 kilowatts per cubic meter for very large arrays), high reliability, platform simplicity (low failure modes), high deployed strength/stiffness when scaled to huge sizes, and high-voltage operation capability. Mega-ROSA is adaptable to all photovoltaic and concentrator flexible blanket technologies, and can readily accommodate standard multijunction and emerging ultra-lightweight IMM (inverted metamorphic) photovoltaic flexible blanket assemblies, as well as ENTECHs Stretched Lens Array (SLA) and DSSs (Deployable Space Systems) FACT, which allows for cost reduction at the array level.
One of the key elements of the flexible rolled-up solar array system is a mechanism to deploy, retract, and store the flexible solar-cell arrays. The selection of components, the design of the mechanism assembly, and the tests that were performed are discussed. During 6 months in orbit, all mission objectives were satisfied, and inflight performance has shown good correlation with preflight analyses and tests.
The Hubble Space Telescope (HST) solar array consists of two identical double roll-out wings designed after the Hughes flexible roll-up solar array (FRUSA) and was developed by the European Space Agency (ESA) to meet specified HST power output requirements at the end of 2 years, with a functional lifetime of 5 years. The requirement that the HST solar array remain functional both mechanically and electrically during its 5-year lifetime meant that the array must withstand 30,000 low Earth orbit (LEO) thermal cycles between approximately +100 and -100 C. In order to evaluate the ability of the array to meet this requirement, an accelerated thermal cycle test in vacuum was conducted at NASA's Marshall Space Flight Center (MSFC), using two 128-cell solar array modules which duplicated the flight HST solar array. Several other tests were performed on the modules. The thermal cycle test was interrupted after 2,577 cycles, and a 'cold-roll' test was performed on one of the modules in order to evaluate the ability of the flight array to survive an emergency deployment during the dark (cold) portion of an orbit. A posttest static shadow test was performed on one of the modules in order to analyze temperature gradients across the module. Finally, current in-flight electrical performance data from the actual HST flight solar array will be tested.
The NASA Lunar Orbital Platform-Gateway (LOP-G), a vital component of NASA’s Artemis program, will serve as a multi-purpose outpost orbiting the Moon. A foundational component of LOP-G is the Power and Propulsion Element (PPE). The PPE is a high-power, +60-kilowatt solar electric propulsion spacecraft that will provide power, high-rate communications, attitude control, and orbital transfer capabilities for the Gateway. The solar array system will utilize 4-junction photovoltaic cell technology on a flexible substrate (roll-out solar array or ROSA) in combination with multiple diode assemblies to combine the power of the solar array strings. NASA’s Marshall Space Flight Center, together with the PPE developer, Maxar, are in the midst of completing a rigorous combined environments test campaign of 3 solar array coupons and 1 array blocking diode board coupon. The campaign includes Ultra-Violet Radiation, Charged Particle Radiation, Ion Erosion, Thermal Cycles, and Electrostatic Discharge tests. The environments are applied in 3 separate incremental stages reflecting the various mission phases: 460 days of Earth-to-Lunar Transit, with much of that time through the Van Allen Belts, 5-years in Lunar Near-Rectilinear Halo Orbit (NRHO) at the Moon, and finally 15-years in Lunar NRHO, which represents the end of the design life. This paper will report on the state of the testing for each coupon, and brief look at the array performance, including some unexpected sensitivities of array blocking diodes.
The study objectives are to analyze in-flight jitter; evaluate different models of the Upper Atmosphere Research Satellite (UARS); and determine jitter prediction accuracy such that adequate (but not excessive) design margins will assume future mission success. The topics are presented in viewgraph form and include the following: UARS chronology; UARS disturbance experiment; microwave limb sounder antenna and mirror time profiles; solar array drive disturbance; roll and yaw jitter correlation with solar array position; solar array rotation; UARS disturbance summary; concept for reduction of jitter effect; jitter reduction using window scheduling; and highlights/lessons learned.
A generalized closed-form equation for the shaded collector fraction in solar arrays on rolling or undulating terrain is provided for single-axis tracking and fixed-tilt systems. The equation accounts for different rotation angles between the shaded and shading trackers, cross-axis slope between the two trackers, and offset between the collector plane and axis of rotation. The validity of the equation is demonstrated through comparison with numerical ray-tracing simulations and remaining minor sources of error are quantified. Additionally, a simple procedure to determine backtracking rotations for each row in an array installed on the rolling terrain (varying in the direction perpendicular to the tracker axes) is provided. The backtracking equation accounts for a desired shaded fraction (including complete shade avoidance) as well as an axis-collector offset. Test cases are provided to facilitate implementation of these equations.
NASA is taking on the bold objective of returning humans to the Moon by 2024. As part of this effort, the Gateway is being constructed to serve as a command center and way-point in cis-lunar space for lunar exploration missions. The Power and Propulsion Element (PPE) is the first element of Gateway to be launched and will generate all the power and propulsion required over its 15-year service life. To achieve these goals, high-power solar arrays and solar electric propulsion will be implemented and demonstrated. The electrical power system (EPS) of Gateway, prominently featuring lightweight Roll Out Solar Arrays (ROSA) with state-of-the-art Z4J solar cells and a central hinge, will be sized for an end-of-life (EOL) power management and distribution capability of over 55 kilowatts (kW). The solar array circuits are being designed in a modular manner with scalability and extensibility to a 300 kW-class mission. NASA Glenn Research Center is managing the PPE contract on which Maxar Technologies, Inc. is responsible for fabricating and demonstrating the spacecraft. This manuscript provides a summary of the electrical power system, with additional discussion of the ROSA power generation.
Feasibility of fabricating 30 watt/pound roll up solar panel array
The influence of large area solar array flexibility on the attitude control of a solar electric spacecraft is analyzed. The spacecraft consists of a rigid central body, two flexible roll-out solar arrays, and a cluster of three electric propulsion engines. Each engine has gimballing or translational capacity, or both, for attitude control purposes. A parametric stability study of various spacecraft configurations was made, using hybrid coordinate techniques in an eigenvalue analysis. Parameters varied were solar array aspect ratio, solar array first natural frequency, solar array rotation angle about the yaw axis, and sensor gain factors. Only the first six modes of solar array vibration were included in the study. The attitude response characteristics of the various spacecraft configurations were obtained by means of a digital computer simulation program of the system's equations of motion. The feasibility of using the thrusters for attitude control of electric propulsion spacecraft is demonstrated. It is also shown that although the dynamics effects of large-area flexible solar arrays can be harmful, changes in the control system parameters can insure stable attitude control.
The Extreme Environment Solar Power (EESP) Project goal was to develop solar cell and solar array design concept technologies for space power applications in high radiation and low solar intensity, low temperature (LILT) environments. NASA missions focused on outer planets, such as Jupiter, are subjected to intense radiation while experiencing less than ten percent of the solar flux relative to a mission in the general vicinity of Earth. Under these conditions, present solar array technology is not as efficient in converting the sun’s energy, and the solar array performance degrades quickly due to the additional radiation exposure. The EESP Project objectives were accomplished through four competitively selected contracts. These contracts were awarded with a Base and two option periods of performance. The Base requirements included System Design and Component Test & Analysis with a duration of nine and one half (9.5) months. The Option I requirements involved the fabrication of test hardware that NASA would evaluate following its delivery, and this period of performance had a duration of thirteen (13) months. The Option II requirements involved the fabrication of a scalable system prototype that can be integrated into a system level application and be demonstrated in a relevant environment. Option II had a duration of fifteen (15) months. The Transformational Array (TA) is an array concept developed by JHU-APL with Deployable Space Systems (DSS), SolAero Technologies and NewForge Technologies that proceeded through all three contract periods. The TA combines the DSS Roll Out Solar Array (ROSA) with Flexible Array Concentrator Technology (FACT) and SolAero’s Inverted Metamorphic Multijunction (IMM) solar cells for operation in the EESP Project environment. To achieve the EESP Project goals, the JHU-APL team conducted several investigations to improve performance of the solar cells and increase their efficiency, reduce outgassing contamination of the concentrators from the solar cell assembly adhesives, and to test the robustness of a sample blanket during deployment and retraction. Additionally, the team performed vibration, thermal cycling, and performance tests at a Standard Power Module (SPM) level. At the end of Option II, the JHU-APL team achieved the following performance metrics: • 39% beginning of life (BOL) cell efficiency at 5 AU and -125 C • 29% end of life (EOL) efficiency at the blanket level at 50 W/m2, -125 C and 4x1015 1 MeV e/cm2 • Increased specific power to 8 W/kg at EOL for the entire array including structure, deployment, and pointing mechanisms • Demonstrated the ability to survive numerous deploy-retract cycles without degradation • Reached a current System-Level Technology Readiness Level, TRL5 This presentation will describe the Transformational Array and component technologies and will discuss future potential uses for the system.
Flexible rolled-up solar array module thermal cycling tests
The LST mission of up to 15 years plus about two years allotment for ground return maintenance could stretch the LST operation to the end of the century. This extended mission life, combined with the large power requirements of the telescope and the scientific instruments, imposes stringent requirements on the electrical power subsystem. The use of an onboard microprocessor for individual battery cell control and monitoring offers a technique that could improve the battery cycle life dramatically. The battery configuration includes spare battery cells which can be switched by the microprocessor to replace failed cells. The microprocessor can also be used for inflight reconditioning of the batteries to increase performance and verify ampere-hour capacity. The Flexible Roll-Up Solar Array (FRUSA) system offers a solar array at an acceptable cost that can stay within weight and volume constraints.
Rideshare, or Multi-Payload launch configurations, are becoming more and more commonplace but access to space is only one part of the overall mission needs. The ability for payloads to achieve their target orbits or destinations can still be difficult and potentially not feasible with on-board propulsion limitations. The High Power Solar Electric Propulsion (HP-SEP) Orbital Maneuvering Vehicle (OMV) provides transfer capabilities for both large and small payload in excess of what is possible with chemical propulsion. Leveraging existing secondary payload adapter technology like the ESPA provides a platform to support Multi-Payload launch and missions. When coupled with HP-SEP, meaning greater than 30 kW system power, very large delta-V maneuvers can be accomplished. The HP-SEP OMV concept is designed to perform a Low Earth Orbit to Geosynchronous Orbit (LEO-GEO) transfer of up to six payloads each with 300kg mass. The OMV has enough capability to perform this 6 kms maneuver and have residual capacity to extend an additional transfer from GEO to Lunar orbit. This high deltaV capability is achieved using state of the art 12.5kW Hall Effect Thrusters (HET) coupled with high power roll up solar arrays. The HP-SEP OMV also provides a demonstration platform for other SEP technologies such as advanced Power Processing Units (PPU), Xenon Feed Systems (XFS), and other HET technologies. The HP-SEP OMV platform can be leveraged for other missions as well such as interplanetary science missions and applications for resilient space architectures.