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IROSA 2B/4B EVA Robotics

The MAGIK Robotic analysis team provides kinematic feasibility assessments and robotic visualizations for the ISS. This animation was created with configurations provided by the CX Team and showcases the robotics for the IROSA install 2B and 4B EVAs. The ExtraVehicular Activities (EVAs) shown include the extraction of the two ISS Roll-Out Solar Arrays (IROSAs) from the ISS Power Augmentation (IPA) carrier by an astronaut on the end of the Space Station Remote Manipulator System (SSRMS) and subsequent handoff to a second astronaut on the ISS port side truss. Extravehicular activities not shown will complete the install of the IROSAs.

Alexander Radford Fryer↗

ROSA and Solar Cell Module Combined Environments Test Plan

Roll-out solar array (ROSA) technology is an emerging component of the future of spacecraft photovoltaic power subsystems. Qualification and risk reduction testing are necessary to demonstrate design worthiness for spaceflight implementation of the array and solar cell modules. Maxar Space LLC and NASA have undertaken a rigorous combined environment (CE) test campaign for a ROSA design expected to be a part of the Power and Propulsion Element (PPE) for the NASA Gateway which will be an outpost orbiting the Moon. The CE tests consist of several simulated space environment exposures associated with the planned mission: UV radiation, electron/proton radiation, xenon ion plume exposures, and vacuum thermal cycling and electrostatic discharge (ESD). These tests are conducted on small coupons consisting of the planned ROSA flight elements, and all tests are performed at the NASA Marshall Space Flight Center. This paper discusses the test plan, requirements for each environment, and the functional testing performed. Of note is a new approach for the induced primary arc used in the ESD testing, which better simulates the plasma expansion during the ESD event. Progress on executing the test plan is presented.

Space Environments Effects Testing↗

SpaceX-26 Animation - Operations from MAGIK AI-4177: SpX-26 (Launch-6)

The MAGIK Robotic analysis team provides kinematic feasibility assessments for the ISS and has produced an animation to evaluate Extravehicular Robotics (EVR) activities for the SpaceX (SpX)-26 flight. The animation also displays the current ISS configuration at the time of the flight. Flight SpX-26 includes a SpaceX Cargo Dragon vehicle docked to Node 2 Zenith (N2Z) International Docking Adapter (IDA) and consists of the delivery of the ISS Roll Out Solar Array (IROSA) mounted to an ISS Power Augmentation (IPA) Carrier. Robotic operations shown include the Space Station Remote Manipulator System (SSRMS) Trunk extraction of the IPA Carrier and maneuvering to the install position on the Payload ORU (Orbital Replacement Unit) Accommodation (POA). There is no disposal payload for this flight.

ISS↗

IROSA 3A EVA Robotics

The MAGIK Robotic analysis team provides kinematic feasibility assessments and robotic visualizations for the ISS. This animation was created with configurations provided by the CX Team and showcases the robotics for the IROSA 3A EVA install. The ExtraVehicular Activity (EVA) shown include the extraction of one ISS Roll-Out Solar Array (IROSA) from the ISS Power Augmentation (IPA) carrier by an astronaut on the end of the Space Station Remote Manipulator System (SSRMS) and subsequent install on the ISS starboard side truss. Operations during the EVA not shown will complete the install of the IROSA.

ISS↗

Analysis of Roll Steering for Solar Electric Propulsion Missions

Nothing is more vital to a spacecraft than power. Solar Electric Propulsion (SEP) uses that power to provide a safe, reliable, and, most importantly, fuel efficient means to propel a spacecraft to its destination. The power performance of an SEP vehicle s solar arrays and electrical power system (EPS) is largely influenced by the environment in which the spacecraft is operating. One of the most important factors that determines solar array power performance is how directly the arrays are pointed to the sun. To get the most power from the solar arrays, the obvious solution is to point them directly at the sun at all times. Doing so is not a problem in deep space, as the environment and pointing conditions that a spacecraft faces are fairly constant and are easy to accommodate, if necessary. However, large and sometimes rapid variations in environmental and pointing conditions are experienced by Earth orbiting spacecraft. SEP spacecraft also have the additional constraint of needing to keep the thrust vector aligned with the velocity vector. Thus, it is important to analyze solar array power performance for any vehicle that spends an extended amount of time orbiting the Earth, and to determine how much off-pointing can be tolerated to produce the required power for a given spacecraft. This paper documents the benefits and drawbacks of perfectly pointing the solar arrays of an SEP spacecraft spiraling from Earth orbit, and how this might be accomplished. Benefits and drawbacks are defined in terms of vehicle mass, power, volume, complexity, and cost. This paper will also look at the application of various solar array pointing methods to future missions. One such pointing method of interest is called roll steering . Roll steering involves rolling the entire vehicle twice each orbit. Roll steering, combined with solar array gimbal tracking, is used to point the solar arrays perfectly towards the sun at all points in the orbit, while keeping the vehicle thrusters aligned in the velocity direction. Roll steering is particularly attractive for a recently proposed mission that involves a spiral trajectory from low Earth orbit (LEO) to the Earth-Moon Lagrange Point 1 (E-M L1). During the spiral, the spacecraft will spend over 300 days experiencing the full spectrum of near-earth environments and solar array pointing conditions. An extensive study of the application of SEP (and roll steering) to this spiral mission is included, highlighting the ultimate goal of reduced vehicle cost and mass. Tools used for this analysis include the Systems Power Analysis for Capability Evaluation (Refs. 1 and 2) (SPACE) electrical power systems code, and SEP trajectory simulation tools developed at NASA Glenn Research Center.

Pederson, Dylan, M.↗

Pterodactyl: Integrated Control Design for Precision Targeting of Deployable Entry Vehicles

Deployable Entry Vehicles (DEVs) enable in-situ scientific exploration at destinations with atmospheres across the solar system. Because they stow in a compact form and deploy only when ready to enter the atmosphere, DEVs relax the volume constraint imposed by rigid aeroshells. This work seeks to do for a DEV what the Wright Brothers did to propel modern day aviation: develop the guidance and control (G&C) methods that will make maneuvering and precision landing of DEV a reality. The Pterodactyl project objective is to deliver an integrated G&C methodology for a DEV, based on a detailed analysis that utilizes a Multi-disciplinary, Design, Analysis and Optimization (MDAO) framework. The current state-of-the-art for blunt body entry, G&C is rooted in the precision landing of vehicles such as Mars Science Laboratory (MSL) and Apollo, which used a propulsive reaction control system (RCS) to steer. Recent research has taken a particular interest in non-propulsive control for DEVs, including direct force control (angle of attack modulation via control surfaces or mass movement) and drag modulation (discrete change in ballistic coefficient). Using the MDAO framework that includes a guidance and control model to explore multiple control concepts for a DEV will shed light on the best design approach for these vehicles. In Pterodactyl, we will complete this study for a novel DEV concept, and then we will fabricate a functional prototype to help validate the design. The project is expected to down-select to a final control architecture by the end of 2018, and complete fabrication of the prototype by the end of 2019.The DEV chosen for detailed study in this project is the Adaptable Deployable Entry and Placement Technology (ADEPT). ADEPT uses a revolutionary 3D-woven carbon fabric that is foldable, can serve as primary structure, and can survive the extreme heating environment of atmospheric entry. The specific configuration of ADEPT under investigation is called Lifting Nano-ADEPT (LNA). LNA is designed for secondary payloads missions that require precision landing either for scientific objectives at a target destination or for payload recovery at Earth.The MDAO framework being created through this research, called COBRA-Pt (Composite Beam Roll-Up Solar Array-Prototype), will combine three critical elements of the system design: a guidance algorithm with Monte Carlo, a parametric control model, and vehicle geometry details. Novel control models being studied are deployable aerodynamic surfaces as well as shape morphing. These concepts will be compared at the system level with a more traditional propulsive RCS by comparing several key performance parameters. Upon completion of the design study, a functional prototype of LNA will be fabricated that will include the integration of guidance software and relevant control actuators. We expect this study will provide critical data that could feed into the development of an Earth-based flight test of LNA. The COBRA-Pt framework will provide a modular system by which to study any DEV concept in any atmosphere.

Smith, Brandon↗

Experiments to evaluate high-temperature rolling as a low-cost process for silicon solar cells

Mechanical rolling (a process used in industry for producing large quantities of metallic sheet and strip) has been suggested for the rapid low-cost manufacture of silicon sheet to be used for photovoltaic power generation equipment, such as solar arrays. The advantages of rolling include: high rates of production, wide sheets as products, good control of dimension, and (in the case of solar grade silicon) minimal development of impurities. Experiments have been performed using high-temperature, high-speed compression of polycrystalline silicon cylinders. Metallography and X-ray diffraction techniques have been used to examine the samples both before and after compression, and a model process has been designed to evaluate the technical practicality and economic feasibility of the method.

Noel, G. T.↗

Quality Assessment of the Nominal Attitude Model of TOPEX/Poseidon Using Quaternion Data

The altimetry mission TOPEX/Poseidon was operational between 1992 and 2005 and provided innovative insight into global and regional sea level changes and their variability. The correct modelling of the spacecraft orbit in precise orbit determination requires detailed information on the attitude of the spacecraft body and the solar array. Since the availability of attitude observations in form of quaternion data for this mission is limited, the nominal orientation model has to be used mainly. In this study, we compare the nominal and quaternion-based approaches of the TOPEX/Poseidon attitude realisation and validate the nominal model w.r.t. the observed attitude. We found good agreement between both approaches in the spacecraft-related roll, pitch, yaw, and solar array angles with slight differences of up to 0.31◦ on average. The best accordance is obtained in the yaw angles. A general angular offset of 0.12◦ and −0.19◦ on average is found in the pitch and solar array angle differences, respectively. Parameters estimated in the orbit computation process also reflect the good agreement between both orientation models with slightly better results when using the observed attitude. However, in some intervals, the nominal model lacks detailed information about the correct attitude. These can be adjusted using the information from the quaternion data. Such intervals indicate off-nominal spacecraft attitude events like drifts or offsets. Purely geometrically analysed, mispointing in the roll and pitch components of about 0.25◦ results in a change of the altimeter phase centre position in the radial direction of about 7 mm, which directly impacts the sea-level heights determined from altimetry measurements.

TOPEX/Poseidon↗

30-kW SEP Spacecraft as Secondary Payloads for Low-Cost Deep Space Science Missions

The Solar Array System contracts awarded by NASA's Space Technology Mission Directorate are developing solar arrays in the 30 kW to 50 kW power range (beginning of life at 1 AU) that have significantly higher specific powers (W/kg) and much smaller stowed volumes than conventional rigid-panel arrays. The successful development of these solar array technologies has the potential to enable new types of solar electric propulsion (SEP) vehicles and missions. This paper describes a 30-kW electric propulsion vehicle built into an EELV Secondary Payload Adapter (ESPA) ring. The system uses an ESPA ring as the primary structure and packages two 15-kW Megaflex solar array wings, two 14-kW Hall thrusters, a hydrazine Reaction Control Subsystem (RCS), 220 kg of xenon, 26 kg of hydrazine, and an avionics module that contains all of the rest of the spacecraft bus functions and the instrument suite. Direct-drive is used to maximize the propulsion subsystem efficiency and minimize the resulting waste heat and required radiator area. This is critical for packaging a high-power spacecraft into a very small volume. The fully-margined system dry mass would be approximately 1120 kg. This is not a small dry mass for a Discovery-class spacecraft, for example, the Dawn spacecraft dry mass was only about 750 kg. But the Dawn electric propulsion subsystem could process a maximum input power of 2.5 kW, and this spacecraft would process 28 kW, an increase of more than a factor of ten. With direct-drive the specific impulse would be limited to about 2,000 s assuming a nominal solar array output voltage of 300 V. The resulting spacecraft would have a beginning of life acceleration that is more than an order of magnitude greater than the Dawn spacecraft. Since the spacecraft would be built into an ESPA ring it could be launched as a secondary payload to a geosynchronous transfer orbit significantly reducing the launch costs for a planetary spacecraft. The SEP system would perform the escape from Earth and then the heliocentric transfer to the science target.

Dawn spacecraft↗

A solar power system for an early Mars expedition

As NASA looks at missions that will expand human presence in the solar system, the power requirements for such missions need to be defined, developed and analyzed. One mission under consideration consists of a 40 day manned Mars surface expedition to perform science experiments. The mission time was centered around an aerocentric longitude (Ls) of 90 deg to lessen the probability of an occurrence of a local or planetary dust storm. The mission site was arbitrarily located at the Martian equator. The power requirements were assumed to be 40 kWe for life support and experiment power during the Martian day and 20 kWe for life support during the Martian night. A solar energy system consisting of roll-out amorphous silicon arrays and a hydrogen-oxygen regenerative fuel cell energy storage system was chosen for the study. The power available from a roll-out array, when plotted against time, approaches a cosine-like curve and depends on both array area and the amount of solar irradiance impinging on its horizontal surface. The array is sized to provide at least 20 KWe when the sun is 12.5 deg above the horizon and ramp up to 140 kWe peak power at Martian noon. In this configuration, the array is capable of supplying 40 KWe continuously to the user for the majority of the Martian day while supplying the excess energy to the electrolyzer portion of the energy storage system. A roll-out, pumped loop radiator system is used to dissipate the waste heat produced by the fuel cell. The power management and distribution system inverts the power from the individual solar array sub-modules and the fuel cell stacks and connects them to a 440 VAC single phase 20 kHz main bus. The total power system is comprised of 80 individual solar array modules with an integral bus and three energy storage modules consisting of fuel cell and electrolyzer stacks, reactant storage tanks, and a roll-out radiator. Power system mass, stowed volume, and deployed area were determined. Day/night power splits of 40/10 kWe, 40/30 kWe, and 40/40 kWe were also considered to determine the impact of a range of nighttime power requirements on the baseline system.

Mckissock, Barbara I.↗

Integrated propulsion for near-Earth space missions. Volume 1: Executive summary

Tradeoffs between electric propulsion system mass ratio and transfer time from LEO to GEO were conducted parametrically for various thruster efficiency, specific impulse, and other propulsion parameters. A computer model was developed for performing orbit transfer calculations which included the effects of aerodynamic drag, radiation degradation, and occultation. The tradeoff results showed that thruster technology areas for integrated propulsion should be directed towards improving primary thruster efficiency in the range from 1500 to 2500 seconds, and be continued towards reducing specific mass. Comparison of auxiliary propulsion systems showed large total propellant mass savings with integrated electric auxiliary propulsion. Stationkeeping is the most demanding on orbit propulsion requirement. At area densities above 0.5 sq m/kg, East-West stationkeeping requirements from solar pressure exceed North-South stationkeeping requirements from gravitational forces. A solar array pointing strategy was developed to minimize the effects of atmospheric drag at low altitude, enabling electric propulsion to initiate orbit transfer at Shuttle's maximum cargo carrying altitude. Gravity gradient torques are used during ascent to sustain the spacecraft roll motion required for optimum solar array illumination. A near optimum cover glass thickness of 6 mils was established for LEO to GEO transfer.

Dailey, C. L.↗

Photovoltaic options for solar electric propulsion

This paper discusses both state-of-the-art and advanced development cell and array technology. Present technology includes rigid, roll-out, and foldout flexible substrate designs, with silicon and GaAs solar cells. The use of concentrator array systems is discussed based on both DOD efforts and NASA work. The benefits of advanced lightweight array technology, for both near term and far term utilization, and of advanced high efficiency thin radiation resistant cells is examined. This includes gallium arsenide/germanium, indium phosphide, and thin film devices such as copper indium disclenide.

Stella, Paul M.↗

The OGO attitude control subsystem redesign as a result of OGO 3 experience. Volume 1: System analysis and design studies

An oscillation in the OGO-3 roll control channel, resulting from the EP-5 and EP-6 boom motion coupling into the control channel and causing loss of attitude control, is investigated. The study includes (1) an analysis of the OGO-3 and OGO-2 flight data to determine the nature and extent of the roll oscillation phenomena, (2) design analysis of the complete attitude control subsystem (ACS) to evolve changes which would prevent recurrences of the coupled ACS boom oscillation observed on OGO-3, and (3) analog simulations to verify the performance of the design changes selected. Portions of OGO-3 and OGO-2 flight data are illustrated and the major flexible body oscillation are identified. A model of the major flexible appendage dynamics is developed and is shown analytically and through analog simulations to reproduce the OGO-3 oscillation phenomena. The design changes which were found necessary are: a reversal delay logic for the roll reaction wheels, widening of the solar array dead zone from 0.5 to 1.0 deg, and modification of the OPEP control loop to include a filter and stabilizing feedback loops.

Mckenna, K. J.↗

Optimal sun-alignment techniques of large solar arrays in electric propulsion spacecraft

Optimum sun-alignment of large solar arrays in electric propulsion spacecraft operating in earth orbit requires periodic roll motions around the thrust axis, synchronized with the apparent conical motion of the sun line. This oscillation is sustained effectively with the aid of gravity gradient torques while only a small share of the total torque is being contributed by the attitude control system. Tuning the system for resonance requires an appropriate choice of moment-of-inertia characteristics. To minimize atmospheric drag at low orbital altitudes the solar array is oriented parallel, or nearly parallel, to the flight direction. This can increase the thrust-to-drag ratio by as much as an order of magnitude. Coupled with optimal roll orientation, this feathering technique will permit use of electric propulsion effectively at low altitudes in support of space shuttle or space station activities and in spiral ascent missions.

Meissinger, H. F.↗

Atomic oxygen effects on SiO(x) coated Kapton for photovoltaic arrays in low earth orbit

Commercially applied SiOx was evaluated as a protective coating for the polyimide Kapton solar array blankets for Space Station Freedom. Three different rolls of coated material were tested in a plasma asher to determine their durability to attack by atomic oxygen. Mass loss data indicated that all of the coatings tested would structurally survive for 15 years in LEO (low earth orbit), except for one which had several uncoated lines across the sample which were caused by ridgelanes in the Kapton. It appears that the size rather than number of defects alone effects the mass loss the most. Careful handling of the material after coating and during processing may be critical for array survival.

Rutledge, Sharon K.↗

Upper Atmosphere Research Satellite attitude disturbances during shadow entry and exit

The Upper Atmosphere Research Satellite (UARS), as with the Landsat-4 and Landsat-5 spacecraft, experiences large attitude disturbances when entering and exiting the Earth's shadow. Previous investigations have provided some evidence linking these disturbances to rapid bending of the solar array but have also raised questions. For example, the magnitudes of the roll attitude disturbances have shown an unmolested asymmetry, and the timing of the disturbances at sunrise appears to disagree with the modeled timing. A better understanding of this phenomenon is important in assessing the implications for UARS science gathering and for future mission design analysis. To this end, UARS attitude, sensor, and actuator data are used to evaluate the disturbances as they vary with solar beta angle and solar array drive angle. The attitude data are examined during specific periods of interest, such as the month in which the solar array was parked in its high-noon position, and are also tracked from the beginning of the mission to determine any trends that may result from changing mass properties due to cryogen boiloff and propellant usage. Attitude rate and torque profiles are derived from inertial reference until data and related to the disturbances seen in the attitude data. The timing of the disturbances with respect to spacecraft sunset and sunrise is characterized to allow event predictions. Stability during the disturbances is discussed in terms of science instrument requirements. Finally, the results are compared with the behavior predicted by models that are based on solar array bending.

Lambertson, M.↗

Flexible, FEP-Teflon covered solar cell module development

Techniques and equipment were developed for the large scale, low-cost fabrication of lightweight, roll-up and fold-up, FEP-Teflon encapsulated solar cell modules. Modules were fabricated by interconnecting solderless single-crystal silicon solar cells and heat laminating them at approximately 300 C between layers of optically clear FEP and to a loadbearing Kapton substrate sheet. Modules were fabricated from both conventional and wraparound contact solar cells. A heat seal technique was developed for mechanically interconnecting modules into an array. The electrical interconnections for both roll-up and fold-up arrays were also developed. The use of parallel-gap resistance welding, ultrasonic bonding, and thermocompression bonding processes for attaching interconnects to solar cells were investigated. Parallel-gap welding was found to be best suited for interconnecting the solderless solar cells into modules. Details of the fabrication equipment, fabrication processes, module and interconnect designs, environmental test equipment, and test results are presented.

Rauschenbach, H. S.↗

Deployable aerospace PV array based on amorphous silicon alloys

The development of the first commercial, ultralight, flexible, deployable, PV array for aerospace applications is discussed. It is based on thin-film, amorphous silicon alloy, multijunction, solar cells deposited on a thin metal or polymer by a proprietary, roll-to-roll process. The array generates over 200 W at AM0 and is made of 20 giant cells, each 54 cm x 29 cm (1566 sq cm in area). Each cell is protected with bypass diodes. Fully encapsulated array blanket and the deployment mechanism weigh about 800 and 500 g, respectively. These data yield power per area ratio of over 60 W/sq m specific power of over 250 W/kg (4 kg/kW) for the blanket and 154 W/kg (6.5 kg/kW) for the power system. When stowed, the array is rolled up to a diameter of 7 cm and a length of 1.11 m. It is deployed quickly to its full area of 2.92 m x 1.11 m, for instant power. Potential applications include power for lightweight space vehicles, high altitude balloons, remotely piloted and tethered vehicles. These developments signal the dawning of a new age of lightweight, deployable, low-cost space arrays in the range from tens to tens of thousands of watts for near-term applications and the feasibility of multi-100 kW to MW arrays for future needs.

Hanak, Joseph J.↗