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NASA NTRS1972

Large area silicon solar array development.

Solar array technology has made significant improvements during the past five years in terms of the design and application of multikilowatt systems and in improvements of the specific power output capabilities of the arrays. The progress in array performance has been primarily due to array design. Experience in building, testing, and flying flexible arrays is giving confidence that they can be safely integrated into many spacecraft designs without deleterious coupling with the spacecraft control system.

Goldsmith, J. V.↗

NASA NTRS2015

Thin, Flexible IMM Solar Array

NASA needs solar arrays that are thin, flexible, and highly efficient; package compactly for launch; and deploy into large, structurally stable high-power generators. Inverted metamorphic multijunction (IMM) solar cells can enable these arrays, but integration of this thin crystalline cell technology presents certain challenges. The Thin Hybrid Interconnected Solar Array (THINS) technology allows robust and reliable integration of IMM cells into a flexible blanket comprising standardized modules engineered for easy production. The modules support the IMM cell by using multifunctional materials for structural stability, shielding, coefficient of thermal expansion (CTE) stress relief, and integrated thermal and electrical functions. The design approach includes total encapsulation, which benefits high voltage as well as electrostatic performance.

Walmsley, Nicholas↗

NASA NTRS1972

Flexible solar-array mechanism

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.

Olson, M. C.↗

NASA NTRS2004

Controllability of Large SEP for Earth Orbit Raising

A six-degree-of-freedom (6DOF) simulation was constructed and exercised for a large solar electric propulsion (SEP) vehicle operating in low Earth orbit Nominal power was 500 kWe, with the large array sizes implied. Controllability issues, including gravity gradient, roll maneuvering for Sun tracking, and flexible arrays, and flight control methods, were investigated. Initial findings are that a SEP vehicle of this size is controllable and could be used for orbit raising of heavy payloads.

Woodcock, Gordon↗

NASA NTRS2000

Terra Flexible Blanket Solar Array Deployment, On-Orbit Performance and Future Applications

The Terra spacecraft (formerly identified as EOS AM1) is the flagship in a planned series of NASA/GSFC (Goddard Space Flight Center) Earth observing system satellites designed to provide information on the health of the Earth's land, oceans, air, ice, and life as a total ecological global system. It has been successfully performing its mission since a late-December 1999 launch into a 705 km polar orbit. The spacecraft is powered by a single wing, flexible blanket array using single junction (SJ) gallium arsenide/germanium (GaAs/Ge) solar cells sized to provide five year end-of-life (EOL) power of greater than 5000 watts at 127 volts. It is currently the highest voltage and power operational flexible blanket array with GaAs/Ge cells. This paper briefly describes the wing design as a basis for discussing the operation of the electronics and mechanisms used to achieve successful on-orbit deployment. Its orbital electrical performance to date will be presented and compared to analytical predictions based on ground qualification testing. The paper concludes with a brief section on future applications and performance trends using advanced multi-junction cells and weight-efficient mechanical components.

Kurland, Richard↗

NASA NTRS2000

Terra Flexible Blanket Solar Array Deployment, On-Orbit Performance and Future Applications

Kurland, Richard↗

NASA NTRS1986

Flexible tactile sensing arrays for robotics: Architectural robustness and yield considerations

No tactile sensor array developed to date fills all, nor even most, of the requirements of: (1) many sensor elements to minimize tactile imaging time, (2) close spacing of small sensing elements for fine spatial discrimination, (3) ability to be molded to a convex fingertip surface for taction on concave surfaces, (4) ability to sense both force and temperature in order to fully mimic biological touch, (5) tolerance to overscale forces without damage, and (6) graceful failure in use, i.e., functional survival of most of the array when part of it is damaged, well. Several investigators have recently developed tactile sensing arrays suitable for imaging shapes on hard flat surfaces, but not well suited for taction on curved surfaces. Others have developed single tactile sensors suitable for incorporation into arrays, which will probably prove uneconomical when large numbers of sensors are needed. Still others have developed flexible capacitive arrays suitable for use on curved surfaces but incapable of obtaining temperature or proximity data. A technology is being developed herein suitable to the achievement of all of the above goals, and to incrementally demonstrate useful steps toward those goals.

Barth, Phillip W.↗

NASA NTRS1982

Miniaturized Cassegrainian concentrator concept demonstration

High concentration ratio photovoltaic systems for space applications have generally been considered impractical because of perceived difficulties in controlling solar cell temperatures to reasonably low values. A miniaturized concentrator system is now under development which surmounts this objection by providing acceptable solar cell temperatures using purely passive cell cooling methods. An array of identical miniaturized, rigid Cassegrainian optical systems having a low f-number with resulting short dimensions along their optical axes are rigidly mounted into a frame to form a relatively thin concentrator solar array panel. A number of such panels, approximately 1.5 centimeters thick, are wired as an array and are folded against one another for launch in a stowed configuration. Deployment on orbit is similar to the deployment of conventional planar honeycomb panel arrays or flexible blanket arrays. The miniaturized concept was conceived and studied in the 1978-80 time frame. Progress in the feasibility demonstration to date is reported.

Patterson, R. E.↗

NASA NTRS1982

Recent advances in thin silicon solar cells

Recent progress in thin (2-4 mils, 50-100 microns) silicon solar cells which extends the capability of the cells into areas of use for possible space missions is reviewed. The production of thin flexible arrays using wrapped-around junction and wrapped-around contact cells is considered. Attention is also given to the formation of cells with very low solar absorptance (alpha-s less than 0.66) through changes in the AR coating, changes in front contact area, and maximizing cell efficiency.

Ho, F.↗

NASA NTRS1984

Investigation of welded interconnection of large area wraparound contacted silicon solar cells

An investigation was conducted to evaluate the welding and temperature cycle testing of large area 5.9 x 5.9 wraparound silicon solar cells utilizing printed circuit substrates with SSC-155 interconnect copper metals and the LMSC Infrared Controlled weld station. An initial group of 5 welded modules containing Phase 2 developmental 5.9 x 5.9 cm cells were subjected to cyclical temperatures of + or 80 C at a rate of 120 cycles per day. Anomalies were noted in the adhesion of the cell contact metallization; therefore, 5 additional modules were fabricated and tested using available Phase I cells with demonstrated contact integrity. Cycling of the later module type through 12,000 cycles indicated the viability of this type of lightweight flexible array concept. This project demonstrated acceptable use of an alternate interconnect copper in combination with large area wraparound cells and emphasized the necessity to implement weld pull as opposed to solder pull procedures at the cell vendors for cells that will be interconnected by welding.

Lott, D. R.↗

NASA NTRS1991

SiOx Protective Coat For Polyimide Sheet

Report and detailed appendix describe protective coat of SiOx (where x is 1.9 - 2.0) on Kapton H(R) polyimide sheet. Surface film protects substrate from bombardment by atomic oxygen. Intended for use as blanket substrate material of flexible array of solar photovoltaic cells on Space Station Freedom.

Banks, Bruce↗

NASA NTRS1994

Simplifying applications software for vision guided robot implementation

A simple approach to robot applications software is described. The idea is to use commercially available software and hardware wherever possible to minimize system costs, schedules and risks. The U.S. has been slow in the adaptation of robots and flexible automation compared to the fluorishing growth of robot implementation in Japan. The U.S. can benefit from this approach because of a more flexible array of vision guided robot technologies.

Duncheon, Charlie↗

NASA NTRS1994

Advances in polycrystalline thin-film photovoltaics for space applications

Polycrystalline, thin-film photovoltaics represent one of the few (if not the only) renewable power sources which has the potential to satisfy the demanding technical requirements for future space applications. The demand in space is for deployable, flexible arrays with high power-to-weight ratios and long-term stability (15-20 years). In addition, there is also the demand that these arrays be produced by scalable, low-cost, high yield, processes. An approach to significantly reduce costs and increase reliability is to interconnect individual cells series via monolithic integration. Both CIS and CdTe semiconductor films are optimum absorber materials for thin-film n-p heterojunction solar cells, having band gaps between 0.9-1.5 ev and demonstrated small area efficiencies, with cadmium sulfide window layers, above 16.5 percent. Both CIS and CdTe polycrystalline thin-film cells have been produced on a laboratory scale by a variety of physical and chemical deposition methods, including evaporation, sputtering, and electrodeposition. Translating laboratory processes which yield these high efficiency, small area cells into the design of a manufacturing process capable of producing 1-sq ft modules, however, requires a quantitative understanding of each individual step in the process and its (each step) effect on overall module performance. With a proper quantification and understanding of material transport and reactivity for each individual step, manufacturing process can be designed that is not 'reactor-specific' and can be controlled intelligently with the design parameters of the process. The objective of this paper is to present an overview of the current efforts at MMC to develop large-scale manufacturing processes for both CIS and CdTe thin-film polycrystalline modules. CIS cells/modules are fabricated in a 'substrate configuration' by physical vapor deposition techniques and CdTe cells/modules are fabricated in a 'superstrate configuration' by wet chemical methods. Both laser and mechanical scribing operations are used to monolithically integrate (series interconnect) the individual cells into modules. Results will be presented at the cell and module development levels with a brief description of the test methods used to qualify these devices for space applications. The approach and development efforts are directed towards large-scale manufacturability of established thin-film, polycrystalline processing methods for large area modules with less emphasis on maximizing small area efficiencies.

Lanning, Bruce R.↗

NASA NTRS2000

Space Solar Power Multi-body Dynamics and Controls, Concepts for the Integrated Symmetrical Concentrator Configuration

Orbiting space solar power systems are currently being investigated for possible flight in the time frame of 2015-2020 and later. Such space solar power (SSP) satellites are required to be extremely large in order to make practical the process of collection, conversion to microwave radiation, and reconversion to electrical power at earth stations or at remote locations in space. These large structures are expected to be very flexible presenting unique problems associated with their dynamics and control. The purpose of this project is to apply the expanded TREETOPS multi-body dynamics analysis computer simulation program (with expanded capabilities developed in the previous activity) to investigate the control problems associated with the integrated symmetrical concentrator (ISC) conceptual SSP system. SSP satellites are, as noted, large orbital systems having many bodies (perhaps hundreds) with flexible arrays operating in an orbiting environment where the non-uniform gravitational forces may be the major load producers on the structure so that a high fidelity gravity model is required. The current activity arises from our NRA8-23 SERT proposal. Funding, as a supplemental selection, has been provided by NASA with reduced scope from that originally proposed.

Glaese, John R.↗

NASA NTRS2011

Large Aperture, Scanning, L-Band SAR

We have developed the first L-band membrane-based active phased array. The antenna is a 16x16 element patch array with dimensions of 2.3mx2.6m. The array uses membrane-compatible Transmit/Receive (T/R) modules for electronic beam steering. We will discuss the antenna design, the fabrication of this large array, the T/R module development, the signal distribution approach and the measured results of the array

phased array↗

NASA NTRS2012

NASA Tech Briefs, September 2012

Topics covered include: Beat-to-Beat Blood Pressure Monitor; Measurement Techniques for Clock Jitter; Lightweight, Miniature Inertial Measurement System; Optical Density Analysis of X-Rays Utilizing Calibration Tooling to Estimate Thickness of Parts; Fuel Cell/Electrochemical Cell Voltage Monitor; Anomaly Detection Techniques with Real Test Data from a Spinning Turbine Engine-Like Rotor; Measuring Air Leaks into the Vacuum Space of Large Liquid Hydrogen Tanks; Antenna Calibration and Measurement Equipment; Glass Solder Approach for Robust, Low-Loss, Fiber-to-Waveguide Coupling; Lightweight Metal Matrix Composite Segmented for Manufacturing High-Precision Mirrors; Plasma Treatment to Remove Carbon from Indium UV Filters; Telerobotics Workstation (TRWS) for Deep Space Habitats; Single-Pole Double-Throw MMIC Switches for a Microwave Radiometer; On Shaft Data Acquisition System (OSDAS); ASIC Readout Circuit Architecture for Large Geiger Photodiode Arrays; Flexible Architecture for FPGAs in Embedded Systems; Polyurea-Based Aerogel Monoliths and Composites; Resin-Impregnated Carbon Ablator: A New Ablative Material for Hyperbolic Entry Speeds; Self-Cleaning Particulate Prefilter Media; Modular, Rapid Propellant Loading System/Cryogenic Testbed; Compact, Low-Force, Low-Noise Linear Actuator; Loop Heat Pipe with Thermal Control Valve as a Variable Thermal Link; Process for Measuring Over-Center Distances; Hands-Free Transcranial Color Doppler Probe; Improving Balance Function Using Low Levels of Electrical Stimulation of the Balance Organs; Developing Physiologic Models for Emergency Medical Procedures Under Microgravity; PMA-Linked Fluorescence for Rapid Detection of Viable Bacterial Endospores; Portable Intravenous Fluid Production Device for Ground Use; Adaptation of a Filter Assembly to Assess Microbial Bioburden of Pressurant Within a Propulsion System; Multiplexed Force and Deflection Sensing Shell Membranes for Robotic Manipulators; Whispering Gallery Mode Optomechanical Resonator; Vision-Aided Autonomous Landing and Ingress of Micro Aerial Vehicles; Self-Sealing Wet Chemistry Cell for Field Analysis; General MACOS Interface for Modeling and Analysis for Controlled Optical Systems; Mars Technology Rover with Arm-Mounted Percussive Coring Tool, Microimager, and Sample-Handling Encapsulation Containerization Subsystem; Fault-Tolerant, Real-Time, Multi-Core Computer System; Water Detection Based on Object Reflections; SATPLOT for Analysis of SECCHI Heliospheric Imager Data; Plug-in Plan Tool v3.0.3.1; Frequency Correction for MIRO Chirp Transformation Spectroscopy Spectrum; Nonlinear Estimation Approach to Real-Time Georegistration from Aerial Images; Optimal Force Control of Vibro-Impact Systems for Autonomous Drilling Applications; Low-Cost Telemetry System for Small/Micro Satellites; Operator Interface and Control Software for the Reconfigurable Surface System Tri-ATHLETE; and Algorithms for Determining Physical Responses of Structures Under Load.

Source record↗

NASA NTRS1979

Method for forming a solar array strip

A flexible solar array strip is formed by a method which lends itself to automatic production techniques. Solder pads are deposited on printed circuitry deposited on a flexible structure. The resultant substrate is stored on a drum from which it is withdrawn and incrementally advanced along a linear path. Solderless solar cells are serially transported into engagement with the pads which are then heated in order to attach the cells to the circuitry. Excess flux is cleaned from the cells which are encapsulated in a protective coating. The resultant array is then spirally wound on a drum.

Mueller, R. I.↗

NASA NTRS2010

Fully Printed High-Frequency Phased-Array Antenna on Flexible Substrate

To address the issues of flexible electronics needed for surface-to-surface, surface-to-orbit, and back-to-Earth communications necessary for manned exploration of the Moon, Mars, and beyond, a room-temperature printing process has been developed to create active, phased-array antennas (PAAs) on a flexible Kapton substrate. Field effect transistors (FETs) based on carbon nanotubes (CNTs), with many unique physical properties, were successfully proven feasible for phased-array antenna systems. The carrier mobility of an individual CNT is estimated to be at least 100,000 sq cm/V(dot)s. The CNT network in solution has carrier mobility as high as 46,770 sq cm/V(dot)s, and has a large current-density carrying capacity of approx. 1,000 mA/sq cm , which corresponds to a high carrying power of over 2,000 mW/ sq cm. Such high carrier mobility, and large current carrying capacity, allows the achievement of high-speed (>100 GHz), high-power, flexible electronic circuits that can be monolithically integrated on NASA s active phasedarray antennas for various applications, such as pressurized rovers, pressurized habitats, and spacesuits, as well as for locating beacon towers for lunar surface navigation, which will likely be performed at S-band and attached to a mobile astronaut. A fully printed 2-bit 2-element phasedarray antenna (PAA) working at 5.6 GHz, incorporating the CNT FETs as phase shifters, is demonstrated. The PAA is printed out at room temperature on 100-mm thick Kapton substrate. Four CNT FETs are printed together with microstrip time delay lines to function as a 2-bit phase shifter. The FET switch exhibits a switching speed of 0.2 ns, and works well for a 5.6-GHz RF signal. The operating frequency is measured to be 5.6 GHz, versus the state-of-the-art flexible FET operating frequency of 52 MHz. The source-drain current density is measured to be over 1,000 mA/sq cm, while the conventional organic FETs, and single carbon nanotube-based FETs, are typically in the mA to mA/sq cm range. The switching voltage used is 1.8 V, while the state-of-the-art flexible FET has a gate voltage around 50 V. The gate voltage can effectively control the source-drain current with an ON-OFF ratio of over 1,000 obtained at a low Vds bias of 1.8 V. The azimuth steering angles of PAA are measured at 0deg, -14.5deg, -30deg, and 48.6deg. The measured far-field patterns agree well with simulation results. The efficiency of the 2-bit 2-element PAA is measured to be 39 percent, including the loss of transmission line, FET switch, and coupling loss of RF probes. With further optimization, the efficiency is expected to be around 50-60 percent.

Chen, Yihong↗