Positive deployable solar array development program - phase 3 Final report
Design and flight certification test data on prototype deployable solar cell array
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Design and flight certification test data on prototype deployable solar cell array
Present concepts for solar power satellites involve dimensions up to tens of kilometers and operating internal currents up to hundreds of kiloamperes. A question addressed is whether the local magnetic fields generated by these strong currents during normal operation can shield the array against impacts by plasma ions and electrons (and from thruster plasmas) which can cause possible losses such as power leakage and surface erosion. One of several prototype concepts was modeled by a long narrow rectangular panel 2 km wide and 20 km long. The currents flow in a parallel across the narrow dimension (sheet current) and along the edge (wire currents). The wire currents accumulate from zero to 100 kiloamp and are the dominant sources. The magnetic field is approximated analytically. The equations of motion for charged particles in this magnetic field are analyzed. The ion and electron fluxes at points on the surface are represented analytically for monoenergetic distributions and are evaluated.
Configuration, rod tradeoff, and deployment parameter studies for design of solar panel array
Reliable brushless direct-drive system design for controlling position and rate of solar power arrays on orbiting spacecraft
Sessions conducted included: polysilicon material requirements; economics; process development in the U.S.; international process development; and polysilicon market and forecasts. Twenty-one papers were presented and discussed.
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A series of mathematical models were developed that describe the electrical behavior of a large solar cell array floating electrically in the low Earth orbit (LEO) space plasma and struck by an arc at a point of negative bias. There are now three models in this series: ARCII, which is a fully analytical, linearized model; ARCIII, which is an extension of ARCIII that includes solar cell inductance as well as load reactance; Nonlinear ARC, which is a numerical model able to treat effects such as non-linearized, i.e., logarithmic solar cell I/V characteristics, conductance switching as a solar cell crosses plasma ground on a voltage excursion and non-ohmic plasma leakage current collection.
Design, testing, and quality control of large-area solar cell array, ground support equipment, and tools
Computer program for solar cell performance prediction in spacecraft power supply systems
Computer program and subroutine for solar panel power output located on Martian surface
Purity requirements for solar cell grade silicon material was developed and defined by evaluating the effects of specific impurities and impurity levels on the performance of silicon solar cells. Also, data was generated forming the basis for cost-tradeoff analyses of silicon solar cell material. Growth, evaluation, solar cell fabrication and testing was completed for the baseline boron-doped Czochralski material. Measurements indicate Cn and Mn seriously degrade cell performance, while neither Ni nor Cu produce any serious reduction in cell efficiency.
The manufacturing methods for photovoltaic solar energy utilization are assessed. Economic and technical data on the current front junction formation processes of gaseous diffusion and ion implantation are presented. Future proposals, including modifying gaseous diffusion and using ion implantation, to decrease the cost of junction formation are studied. Technology developments in current processes and an economic evaluation of the processes are included.
A concept is presented for encapsulating solar cells between two layers of glass either individually, in panels, or in a continuous process. The concept yields an integral unit that is hermetically sealed and that is tolerant to high temperature thermal cycling and to particulate radiation. Data are presented on both high temperature solar cells and special glasses that soften at low temperatures for use with the concept. The results of encapsulating experiments are presented which show the successful application of the concept to the special high temperature cells. The mechanical feasibility of encapsulating 2 mil cells between two layers of 2 mil glass is also demonstrated.
The technical feasibility of producing solar cell quality sheet silicon to meet the DOE 1986 cost goal of 70 cents/watt was investigated. The silicon on ceramic approach is to coat a low cost ceramic substrate with large grain polycrystalline silicon by unidirectional solidification of molten silicon. Results and accomplishments are summarized.
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Specific design features to reduce cell mass, lower panel operating temperatures, and improve power to mass ratios for silicon solar cell arrays in space applications are presented. Because mass constraints limit payload capacity for launch into GEO, graphite/epoxy structures combined with high performance Si cells are needed to deliver a power/mass ratio of 265 W/kg, notably for Solar Electric Propulsion systems, compared with existing level of 65 W/kg. Shallow diffusion and back surface field cell technology have raised cell efficiencies to 15%, with a back emissivity of 1.64. Structural design requirements comprise Shuttle interface compatibility, full ground test capability, low mass, and high stiffness. Three array alternatives are discussed, and the STACBEAM configuration, which consists of a triangular truss and a piston deployer with folding accomplished on simple hinges, provides 0.2 Hz stiffness and achieves the design power/mass goals.
A machine is described for attaching solar cells to a flexable substrate on which printed circuitry has been deposited. The strip is fed through: (1) a station in which solar cells are elevated into engagement with solder pads for the printed circuitry and thereafter heated by an infrared lamp; (2) a station at which flux and solder residue is removed; (3) a station at which electrical performance of the soldered cells is determined; (4) a station at which an encapsulating resin is deposited on the cells; (5) a station at which the encapsulated solar cells are examined for electrical performance; and (6) a final station at which the resulting array is wound on a takeup drum.
Large arrays are rapidly assembled from individual solar cells by automated production line developed for NASA's Jet Propulsion Laboratory. Apparatus positions cells within array, attaches interconnection tabs, applies solder flux, and solders interconnections. Cells are placed in either straight or staggered configurations and may be connected either in series or in parallel. Are attached at rate of one every 5 seconds.