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Proposed economical manufacture of solar-cell arrays involves parallel, planar weaving of filaments made of doped silicon fibers with diffused radial junction. Each filament is a solar cell connected either in series or parallel with others to form a blanket of deposited grids or attached electrode wire mesh screens.
Three lightweight solar cell arrays have been fabricated with a high power-to-weight ratio. These arrays incorporate resistance welded interconnections, improved antireflection coating on the solar cell and lightweight substrates. Two of the substrates were constructed of magnesium with different structural geometry, while the third substrate was conventional aluminum honeycomb. All arrays utilized thin solar cells having a titanium-palladium-silver contact system and an antireflection coating of titanium oxide. The cells were welded with silver plated molybdenum interconnections. The two arrays having magnesium substrates exhibited a power/weight of 70.4 W/kg (32 W/lb.) and 81 W/kg (36.8 W/lb.), while the conventional array demonstrated a power/weight of 45.2 W/kg (20.6 W/lb.).
Future missions to deep space, such as those to the outer planets (Jupiter, Saturn, etc.), which would rely on solar photovoltaic power, would need extremely large solar arrays to produce sufficient power for their operations because solar intensity is so low at those locations. Hence any additional power that would be needed for thermal control is extremely limited. Previous deep space missions like Juno (to Jupiter) required almost 200 W of electrical power for thermal control. This is prohibitively large for many future mission concepts, and leads to them needing very large solar arrays. For Saturn, where the solar flux is 1/4th the flux at Jupiter, this would entail an extremely large increase in the solar array size to accommodate the need for thermal survival power, which would be prohibitively large in size and mass, and very expensive. Hence there is a need to come up with a thermal architecture and design options that would not need such prohibitively large thermal power levels. One solution relies on harvesting the pre-existing waste heat from all the heat dissipation that would be present from operation of electronics, instruments, etc. for their own functionality. For example, for a generic Saturn mission, the various electronics would already dissipate about 200 Watts of heat that is simply "thrown away" to space from the spacecraft surfaces. The amount of thermal power that would be required for the safe thermal control of components within the spacecraft in deep space would be roughly of this magnitude for this class of spacecraft. So it makes good sense to try to harvest the waste heat and employ it to maintain the temperatures of all the components within their allowable limits. In particular, propulsion systems typically need to be kept above their freezing limits, around room temperature (15 C). Electronics needs to be kept typically above -40 C and batteries above -20 C. The next question becomes how to harvest this waste heat and direct it to the components that would need it for their survival. The proposed system utilizes a mechanically pumped, single phase fluid loop to pick up the waste heat from components attached to this loop's tubing and then directed to a thermal flask that has tubing attached to it. The thermal flask is cylindrically shaped and contains essentially all systems and components in the spacecraft within it, with the exception of the solar array, antennae, thrusters and various apertures of instruments, etc. to allow them an unobstructed view of space. Waste heat from the heat-dissipating components warms up the fluid and is carried to the flask surface and deposited on it via the fluid loop's flow. The entire flask is covered with Multi-Layered Insulation (MLI) to minimize the heat loss from the flask and allow it to remain warm. Hence the flask essentially creates a thermal environment within which the spacecraft components reside. The temperature of the components within the flask is then essentially the same as the temperature of the flask. This approach could be a very enabling feature for deep space missions. This paper describes the approach utilized for this thermal architecture, along with its mechanical and implementation aspects. Additionally it will compare and contrast this approach with the more conventional solutions utilized earlier.
In 1986 during the flat-plate solar array project, silicon solar cells 4.0 sq cm in area were fabricated at the Jet Propulsion Laboratory (JPL) with a conversion efficiency of 20.1 percent (AM1.5-global). Sixteen cells were processed with efficiencies measuring 19.5 percent (AM1.5 global) or better. These cells were produced using refined versions of conventional processing methods, aside from certain advanced techniques that bring about a significant reduction in a major mechanism (surface recombination) that limits cell efficiency. Wacker Siltronic p-type float-zone 0.18-ohm-cm wafers were used. Conversion efficiencies in this range have previously been reported by other researchers, but generally on much smaller (0.5 vs. 4.0 cm) devices which have undergone sophisticated and costly processing steps. An economic analysis is presented of the potential payoffs for this approach, using the Solar Array Manufacturing Industry Costing Standards (SAMICS) methodology. The process sequence used and the assumptions made for capturing the economies of scale are presented.
As a result of man's venturing into space, the local debris contributed by his presence exceeds, at some orbital altitudes, that of the natural component. Man's contribution ranges from fuel residue to large derelect satellites that weigh many kilograms. Current debris models are able to predict the growth of the 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 maximum velocity of the man-made component is in the 14-16 km/s range. The Long Duration Exposure Facility (LDEF) has verified that the 'high probability of impact' particles are in the microgram to milligram range. These particles can have 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 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 is currently being used to study impact phenomena on Space Station Freedom's solar array structure, other solar array materials, potential structural materials for use in the station, electrical breakdown in the space environment, and as a means of clarifying or duplicating the impact phenomena on the LDEF surfaces. The results of these experiments are described in terms of the mass/velocity distribution incident on selected samples, crater dynamics, and sample geometry.
Plasma ground testing results, conducted at the Glenn Research Center (GRC) National Plasma Interaction (N-PI) Facility, are presented for a number of thin-film photovoltaic cells. The cells represent a mix of promising new technologies identified by the Air Force Research Laboratory (AFRL) under the CYGNUS Space Science Technology Experiment (SSTE-4) Program. The current ground tests are aimed at characterizing the performance and survivability of thin film technologies in the harsh low earth orbital space environment where they will be flown. Measurements of parasitic current loss, charging/dielectric breakdown of cover-slide coatings and arcing threshold tests are performed for each individual cell. These measurements are followed by a series of experiments designed to test for catastrophic arc failure mechanisms. A special type of power supply, called a solar array simulator (SAS) with adjustable voltage and current limits on the supply s output, is employed to bias two adjacent cells at a predetermined voltage and current. The bias voltage is incrementally ramped up until a sustained arc results. Sustained arcs are precursors to catastrophic arc failure where the arc current rises to a maximum value for long timescales often ranging between 30 to 100 sec times. Normal arcs by comparison, are short lived events with a timescale between 10 to 30 sec. Sustained arcs lead to pyrolization with extreme cell damage and have been shown to cause the loss of entire array strings in solar arrays. The collected data will be used to evaluate the suitability of thin-film photovoltaic technologies for future space operations.
The useful operational range of photovoltaic solar arrays has been limited to 1.5 AU (Mars orbit) due primarily to solar intensity constraints. Preliminary results indicate that the use of concentrator mirrors in conjunction with solar arrays can extend the practical operating range of photovoltaic space power sources to at least 9.5 AU (Saturn orbit). Various aspects of concentrator-enhanced photovoltaic arrays such as size, structure, thermal characteristics, intensity uniformity, pointing accuracy requirements, deployment methods, power performance and system mass are presented. Based on this information, concentrator-enhanced photovoltaic arrays are superior, with respect to power-to-mass and cost, to existing power sources used for deep space missions. The sensitivity of concentrator-enhanced solar arrays to particulate radiation was also examined for representative deep space missions. Results are presented which show that a radiation-degraded, deep space, concentrator-enhanced solar array's performance exceeds that of existing RTG power sources.
Operation of solar cell arrays in dilute streaming plasmas
A shuttle flight experiment, the purpose of which is to obtain space data on the interaction of a high voltage solar array with the ambient space plasma is addressed. This flight experiment is a reflight of the solar array flight experiment, SAFE, except that three active solar array panels, electron release devices and plasma diagnostics are added. This experiment, SAFE 2, evaluates power loss due to parasitic current collected by the solar array, arcing on the solar array and perturbations to the plasma which may increase power loss and disturb plasma and charged particle science acquisition.
The Hubble Space Telescope (HST) was launched April 24, 1990, and was deployed April 25 into low Earth orbit (LEO). It was soon discovered that the metal poles holding the solar arrays were expanding and contracting as the telescope orbited the Earth passing between the sunlight and the Earth s shadow. The expansion and contraction, although very small, was enough to cause the telescope to shake because of thermal-induced jitters, a detrimental effect when trying to take pictures millions of miles away. Therefore, the European Space Agency (ESA, the provider of the solar arrays) built new solar arrays (SA-11) that contained bi-stem thermal shields which insulated the solar array metal poles. These thermal shields were made of 2 mil thick aluminized-Teflon fluorinated ethylene propylene (FEP) rings fused together into a circular bellows shape. The new solar arrays were put on the HST during an extravehicular activity (EVA), also called an astronaut space walk, during the first servicing mission (SM1) in December 1993. An on-orbit photograph of the HST with the SA-11, and a close up of the bellows-like structure of the thermal shields is provided in Figure 1.
The influence from the ambient plasma on the arc characteristics of a negatively biased solar cell array was investigated. The arc characteristics examined were the peak current during an arc, the decay time as the arc terminates, and the charge lost during the arc. These arc characteristics were examined in a nitrogen plasma with charge densities ranging from 15,000 to 45,000 cu cm. Background gas pressures ranged from 8x1,000,000 to 6x100,000 torr. Over these ranges of parameters no significant effect on the arc characteristics were seen. Arc characteristics were also examined for three gas species: helium, nitrogen and argon. The helium arcs have higher peak currents and shorter decay times than nitrogen and argon arcs. There are slight differences in the arc characteristics between nitrogen and argon. These differences may be caused by the differences in mass of the respective species. Also, evidence is presented for an electron emission mechanism appearing as a precursor to solar array arcs. Occassionally the plasma generator could be turned off, and currents could still be detected in the vacuum system. When these currents are presented, arcs may occur.
The influence from the ambient plasma on the arc characteristics of a negatively biased solar cell array was investigated. The arc characteristics examined were the peak current during an arc, the decay time as the arc terminates, and the charge lost during the arc. These arc characteristics were examined in a nitrogen plasma with charge densities ranging from 15,000 to 45,000 cu cm. Background gas pressures ranged from 8x1,000,000 to 6x100,000 torr. Over these ranges of parameters no significant effect on the arc characteristics were seen. Arc characteristics were also examined for three gas species: helium, nitrogen and argon. The helium arcs have higher peak currents and shorter decay times than nitrogen and argon arcs. There are slight differences in the arc characteristics between nitrogen and argon. These differences may be caused by the differences in mass of the respective species. Also, evidence is presented for an electron emission mechanism appearing as a precursor to solar array arcs. Occasionally the plasma generator could be turned off, and currents could still be detected in the vacuum system. When these currents are presented, arcs may occur.
Power processing units (PPU's) in an electric propulsion system provide many challenging integration issues. The PPU must provide power to the electric thruster while maintaining compatibility with all of the spacecraft power and data systems. Inefficiencies in the power processor produce heat, which must be radiated to the environment in order to ensure reliable operation. Although PPU efficiencies are generally greater than 0.9, heat loads are often substantial. This heat must be rejected by thermal control systems which generally have specific masses of 15-30 kg/kW. PPU's also represent a large fraction of the electric propulsion system dry mass. Simplification or elimination of power processing in a propulsion system would reduce the electric propulsion system specific mass and improve the overall reliability and performance. A direct drive system would eliminate all or some of the power supplies required to operate a thruster by directly connecting the various thruster loads to the solar array. The development of concentrator solar arrays has enabled power bus voltages in excess of 300 V which is high enough for direct drive applications for Hall thrusters such as the Stationary Plasma Thruster (SPT). The option of solar array direct drive for SPT's is explored to provide a comparison between conventional and direct drive system mass.
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.
This study used high fidelity computer simulation to investigate the lighting conditions, specifically the solar radiation flux over the surface, on Phobos. Ephemeris data from the Jet Propulsion Laboratory (JPL) DE405 model was used to model the state of the Sun, Earth, Moon, and Mars. An occultation model was developed to simulate Phobos' self-shadowing and its solar eclipses by Mars. The propagated Phobos state was compared with data from JPL's Horizon system to ensure the accuracy of the result. Results for Phobos lighting conditions over one Martian year are presented, which include the duration of solar eclipses, average solar radiation intensity, surface exposure time, and radiant exposure for both sun tracking and fixed solar arrays. The results show that: Phobos' solar eclipse time varies throughout the Martian year, with longer eclipse durations during the Martian northern spring and fall seasons and no eclipses during the Martian northern summer and winter seasons; solar radiation intensity is close to minimum in late spring and close to maximum in late fall; exposure time per orbit is relatively constant over the surface during the spring and fall but varies with latitude during the summer and winter; and Sun tracking solar arrays generate more energy than a fixed solar array. A usage example of the result is also present in this paper to demonstrate the utility.
Thin film cadmium sulfide solar cell array on plastic substrate development
During an Extravehicular Activity (EVA), if the Extravehicular Mobility Unit (EMU) makes galvanic contact with the International Space Station (ISS), a negative Floating Potential (FP) can lead to an arcing hazard when it exceeds -45.5 V, and a positive FP can produce a DC current high enough to stimulate the astronaut’s muscles (5 mA), and also cause a hazard. The Boeing Space Environments team developed and utilizes a Plasma Interaction Model (PIM) in order to calculate the ISS FP based on the plasma environment, ISS velocity, geomagnetic field, solar array and ISS orientation, and solar array regulation to support EVA planning operations. Presently, the model excludes the sheath capacitance, resulting in the total potential drop being across the dielectric surface of the vehicle. Data from the Floating Potential Measurement Unit (FPMU) show this assumption to be generally true. However, Rapid Charging Events (RCE) are often observed in the FPMU data at eclipse exit when the electron number density, Ne, is low (less than 5(sub e)10 m (exp-3)). During these events, the FP can rise more than 40 V in one to five seconds. There is then a relaxation phase where the FP drops back to the normal FP values. The PIM model is not capable of producing these RCEs. It was thought that the inclusion of the sheath in PIM could improve the charging predictions, particularly as related to RCEs. A parametric study was performed to determine what portion of the measured FP is across the sheath for a range of Ne experienced by the ISS, and if the inclusion of the sheath in PIM is necessary. Results show that the potential drop across the sheath is negligible at times when the N(sub e) is greater than 1(sub e)11 m-3. However, there appears to be a transitional region between 1(sub e)10 m(exp -3) and 1(sub e)11 m(exp -3) where the sheath capacitance becomes more significant. During those conditions the potential drop across the sheath can be larger than the potential drop across the dielectric for short periods (1-5 seconds). These results agree remarkably well with measurements made by the FPMU. The inclusion of the sheath explains why high charging measurements occur when the Ne is low at eclipse exit and even times when the solar arrays are not a significant driver (i.e., potentials often rise as the ISS flies through spread-F). Results also show that the RCEs are not a safety concern because the potential drop across the dielectric surface does not exceed -45.5 V. In that case, the EMU would not arc. This gives high confidence in the low probability of an arcing hazard occurring.
On the second flight of the INTELSAT V spacecraft the time required for successful deployment of the north solar array was longer than originally predicted. The south solar array deployed as predicted. As a result of the difference in deployment times a series of experiments was conducted to locate the cause of the difference. Deployment rate sensitivity to hinge friction and temperature levels was investigated. A digital computer simulation of the deployment was created to evaluate the effects of parameter changes on deployment. Hinge design was optimized for nominal solar array deployment time for future INTELSAT V satellites. The nominal deployment times of both solar arrays on the third flight of INTELSAT V confirms the validity of the simulation and design optimization.