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Structural problems in high power solar photovoltaic arrays technology, discussing configuration, materials selection, thermal control coatings and tests results
Current debris models are able to predict the growth of the space debris problem and suggest that spacecraft must employ armor or bumper shields for some orbital altitudes now and that the problem will become worse as a function of time. The practical upper limit to the velocity distribution is on the order of 40 km/s and is associated with the natural environment. The velocity distribution of the man-made component peaks at 9-10 km/s with maximum velocity in the 14-16 km/s range. Experience in space has verified that the "high probability of impact" particles are in the microgram to milligram range. These particles can have very significant effects on coatings, insulators, and thin metallic layers. The surface of thick materials becomes pitted and the local debris component is enhanced by ejecta from the impact events. In this paper, the HYPER facility is described which produces a reasonable simulation of the man-made space debris spectrum in a controlled environment. The facility capability is discussed in terms of drive geometry, energetics, velocity distribution, diagnostics, and projectile/debris loading. The facility has been used to study impact phenomena on Space Station Freedom's solar array structure, the calibration of space debris collectors, other solar array materials, potential structural materials for use in space, electrical breakdown in the space environment, and as a means of clarifying or duplicating the impact phenomena on surfaces which have been exposed in space.
Engineering mechanics in structural design of silicon solar arrays
Efficient structures for geosynchronous spacecraft solar arrays were investigated. The STACBEAM (stacking triangular articulated compact beam) concept was selected. The primary component, the solar array blanket, is stored in a folded configuration and is deployed by controlled linear extension. Blanket stiffness is attained by axially tensioning the blanket and by providing periodic lateral ribs and standoffs which attach the blanket to the beam at several places along its length. The STACBEAM deploys sequentially (one bay at a time) using a deployer of sufficient rigidity so that beam stiffness is not degraded during deployment. The beam does not rotate during deployment, thus making blanket beam attachment possible in the packaged condition. In addition to high bending stiffness, the STACBEAM possesses high torsional rigidity due to nonflexible diagonals. The concept is adaptable to various size and loading requirements by changing member diameter and baylength, thus affecting the ratio of packaged and deployed length.
A candidate configuration for a controls experiment on the Space Technology Experiments Platform (STEP) is described. The elements of the experiment are the mast, the solar array, and an articulation module between the two. The characteristic dimensions are very compatible for integration on a pallet such a STEP's proposed configuration. The controls' objective would be the measurement of orbiter interaction as well as the system identification of the appendages. The flight experiment configuration would also provide a test bed for various active vibration controls concepts. The instrumentation being considered would measure accelerations, strains, displacements, and temperatures. The deployable mast has eight elements defining a structural bay. Uniaxial measurements would be required to define loads at a cross section of the structure. Displacements due to thermal distortion of the mast and the local state of the solar concentrator may be measured by an optical ranging technique from the orbiter aft flight deck.
Space structures, such as the space station solar arrays, must be extremely lightweight, flexible structures. Accurate prediction of the natural frequencies and mode shapes is essential for determining the structural adequacy of components, and designing a control system. The tension preload in the blanket of photovoltaic solar collectors, and the free/free boundary conditions of a structure in space, causes serious reservations on the use of standard finite element techniques of solution. In particular, a phenomena known as grounding, or false stiffening, of the stiffness matrix occurs during rigid body rotation. The grounding phenomena is examined in detail. Numerous stiffness matrices developed by others are examined for rigid body rotation capability, and found lacking. Various techniques are used for developing new stiffness matrices from the rigorous solutions of the differential equations, including the solution of the directed force problem. A new directed force stiffness matrix developed by the author provides all the rigid body capabilities for the beam in space.
Strong supporting structures for flat solar photovoltaic arrays built with such commonly available materials as wood and galvanized steel sheet. Structures resist expected static loads from snow and ice as well as dynamic loads from winds and even Earthquake vibrations. Supporting structure uses inexpensive materials. Parts prefabricated to minimize assembly work in field.
At the lunar south pole, solar arrays elevated by truss towers are exposed to near continuous sunlight since the sun remains near the horizon. Recent studies suggest that tower heights on the order of 50 m are needed to meet the power requirements to support a sustained lunar presence. While eventually towers may be constructed using materials sourced in-situ, initially structural elements will likely be brought from the Earth, deployed, and assembled. Thermoplastic composites offer the benefit of high specific stiffness and strength properties along with welding for assembly joints, and therefore represent a promising material system for this application. The focus of this paper is on the structural sizing of such towers. A set of expressions based on beam theory are presented for preliminary sizing of the truss tower structure for strength and buckling. The loading condition that drives sizing is base excitation resulting from moonquakes. A point design, developed through finite element analysis, verifies the analytical sizing routine and shows the importance of joints. The results show a viable point design and highlight the factors most significant in the structural sizing.
At the lunar south pole, solar arrays elevated by truss towers are exposed to near continuous sunlight since the sun remains near the horizon. Recent studies suggest that tower heights on the order of 50 m are needed to meet the power requirements to support a sustained lunar presence. While eventually towers may be constructed using materials sourced in-situ, initially structural elements will likely be brought from the Earth, deployed, and assembled. Thermoplastic composites offer the benefit of high specific stiffness and strength properties along with welding for assembly joints, and therefore represent a promising material system for this application. The focus of this paper is on the structural sizing of such towers. A set of expressions based on beam theory are presented for preliminary sizing of the truss tower structure for strength and buckling. The loading condition that drives sizing is base excitation resulting from moonquakes. A point design, developed through finite element analysis, verifies the analytical sizing routine and shows the importance of joints. The results show a viable point design and highlight the factors most significant in the structural sizing.
The Photogrammetric Appendage Structural Dynamics Experiment was designed, developed, and flown to demonstrate and prove measurement of the structural vibration response of a Russian Space Station Mir solar array using photogrammetric methods. The experiment flew on the STS-74 Space Shuttle mission to Mir in November 1995 and obtained video imagery of solar array structural response to various excitation events. The video imagery has been digitized and triangulated to obtain response time history data at discrete points on the solar array. This data has been further processed using the Eigensystem Realization Algorithm modal identification technique to determine the natural vibration frequencies, damping, and mode shapes of the solar array. The results demonstrate that photogrammetric measurement of articulating, non-optically targeted, flexible solar arrays and appendages is a viable, low-cost measurement option for the International Space Station.
The Photogrammetric Appendage Structural Dynamics Experiment was designed, developed, and flown to demonstrate and prove measurement of the structural vibration response of a Russian Space Station Mir solar array using photogrammetric methods. The experiment flew on the STS-74 Space Shuttle mission to Mir in November 1995 and obtained video imagery of solar array structural response to various excitation events. The video imagery has been digitized and triangulated to obtain response time history data at discrete points on the solar array. This data has been further processed using the Eigensystem Realization Algorithm modal identification technique to determine the natural vibration frequencies, damping, and mode shapes of the solar array. The results demonstrate that photogrammetric measurement of articulating, nonoptically targeted, flexible solar arrays and appendages is a viable, low-cost measurement option for the International Space Station.
The Space Acceleration Measurement System (SAMS) collected acceleration data in support of the Mechanics of Granular Materials experiment during the STS-79 Mir docking mission, September 1996. STS-79 was the first opportunity to record SAMS data on an Orbiter while it was docked to Mir. Crew exercise activities in the Atlantis middeck and the Mir base module are apparent in the data. The acceleration signals related to the Enhanced Orbiter Refrigerator Freezer had different characteristics when comparing the data recorded on Atlantis on STS-79 with the data recorded on Mir during STS-74. This is probably due, at least in part, to different transmission paths and SAMS sensor head mounting mechanisms. Data collected on Atlantis during the STS-79 docking indicate that accelerations due to vehicle and solar array structural modes from Mir transfer to Atlantis and that the structural modes of the Atlantis-Mir complex are different from those of either vehicle independently. A 0.18 Hz component of the SAMS data, present while the two vehicles were docked, was probably caused by the Mir solar arrays. Compared to Atlantis structural modes of about 3.9 and 4.9 Hz, the Atlantis-Mir complex has structural components of about 4.5 and 5.1 Hz. After docking, apparent structural modes appeared in the data at about 0.8 and 1.8 Hz. The appearance, disappearance, and change in the structural modes during the docking and undocking phases of the joint Atlantis-Mir operations indicates that the structural modes of the two spacecraft have an effect on the microgravity environment of each other. The transfer of structural and equipment related accelerations between vehicles is something that should be considered in the International Space Station era.
As flexible thin film photovoltaic (FTFPV) cell technology is developed for space applications, integration into a viable solar array structure that optimizes the attributes of this cell technology is critical. An advanced version of ABLE'sS UltraFlex solar array platform represents a near-term, low-risk approach to demonstrating outstanding array performance with the implementation of FTFPV technology. Recent studies indicate that an advanced UltraFlex solar array populated with 15% efficient thin film cells can achieve over 200 W/kg EOL. An overview on the status of hardware development and the future potential of this technology is presented.
A number of structurally efficient configurations for wing-type solar arrays are developed by a combination of deepening the planform of the blanket and structure and by partitioning the blanket with battens and frequent attachments to the support structure. This technique reduces the tension required to avoid a low natural frequency for the blanket, and the load reduction results in a lighter structure. The use of three different structures are investigated: the Astromast, the Extendible Support Structure (ESS), and a new beam called the STACBEAM (Stacking Triangular Articulated Compact Beam) and their relative performances are compared. The investigation of the STACBEAM is emphasized because its sequential deployment is more reliable for very long systems, and its linear deployment facilitates local attachments to the blanket and the development of a low mass deployer.
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.
This presentation reviews Solar Electric Propulsion (SEP) Mission Architectures with a slant towards power system technologies and challenges. The low-mass, high-performance attributes of SEP systems have attracted spacecraft designers and mission planners alike and have led to a myriad of proposed Earth orbiting and planetary exploration missions. These SEP missions are discussed from the earliest missions in the 1960's, to first demonstrate electric thrusters, to the multi-megawatt missions envisioned many decades hence. The technical challenges and benefits of applying high-voltage arrays, thin film and low-intensity, low-temperature (LILT) photovoltaics, gossamer structure solar arrays, thruster articulating systems and microsat systems to SEP spacecraft power system designs are addressed. The overarching conclusion from this review is that SEP systems enhance, and many times enable, a wide class of space missions.
Structural concepts for deploying and supporting lightweight solar-array blankets for geosynchronous electrical power are evaluated. It is recommended that the STACBEAM solar-array system should be the object of further study and detailed evaluation. The STACBEAM system provides high stiffness at low mass, and with the use of a low mass deployment mechanism, full structural properties can be maintained throughout deployment. The stowed volume of the STACBEAM is acceptably small, and its linear deployment characteristic allows periodic attachments to the solar-array blanket to be established in the stowed configuration and maintained during deployment.
Solar power systems have enabled dazzling planetary science missions to much of the Solar System. This chapter outlines the types of solar array structures that have been used on U.S.-led robotic planetary science missions since the beginning of the space age, including several in development for future launch. The first solar-powered spacecraft employed body-mounted solar cells but designs quickly moved to extended panels to generate more electrical power. Early “paddle” designs were replaced by deployable twin rectangular “wings” which are still common in science missions and nearly ubiquitous in commercial telecommunications satellites. The increasing complexity of science missions investigating the nature of the space environment drove the development of the solar-powered satellites from the very beginning, and unique mission requirements to explore ever more distant and harsher regions of our solar system continue to drive innovations in spacecraft design, including solar arrays. This general progression to ever larger solar arrays to power ever more sophisticated spacecraft in ever harsher environments, punctuated by missions that emphasize lower cost and complexity, is a pattern that began in the 1960s and continues to this day. This chapter describes the solar array configurations used on deep space missions, with an emphasis on NASA’s planetary science missions, including specific design requirements that led to individual design selections. Future trends are also described.