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Search indexed NASA NTRS and DOE OSTI research on propulsion, heat transfer, battery materials and energy systems. Follow report and document links to the original sources.

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All sourcesNASA NTRSDOE OSTI
DOE OSTI2021

Gaming the beamlines—employing reinforcement learning to maximize scientific outcomes at large-scale user facilities

Abstract Beamline experiments at central facilities are increasingly demanding of remote, high-throughput, and adaptive operation conditions. To accommodate such needs, new approaches must be developed that enable on-the-fly decision making for data intensive challenges. Reinforcement learning (RL) is a domain of AI that holds the potential to enable autonomous operations in a feedback loop between beamline experiments and trained agents. Here, we outline the advanced data acquisition and control software of the Bluesky suite, and demonstrate its functionality with a canonical RL problem: cartpole. We then extend these methods to efficient use of beamline resources by using RL to develop an optimal measurement strategy for samples with different scattering characteristics. The RL agents converge on the empirically optimal policy when under-constrained with time. When resource limited, the agents outperform a naive or sequential measurement strategy, often by a factor of 100%. We interface these methods directly with the data storage and provenance technologies at the National Synchrotron Light Source II, thus demonstrating the potential for RL to increase the scientific output of beamlines, and layout the framework for how to achieve this impact.

36 MATERIALS SCIENCE↗
DOE OSTI2017

Applications of data mining technology to enhance O and M: automatic planning of electrical isolation with deep learning - 255

Data mining technology is now readily available, thanks to high powered, low cost computing resource and useful coding tools. We study several applications of data mining to enhance operation and maintenance (O and M), such as abnormality prediction, efficiency diagnosis, document traceability, image recognition, etc. In field support, we try automatic planning of electrical isolation with deep learning. Currently, a skilled engineer plans electrical isolation procedure with hundreds of the circuit diagrams and the related documents, taking man-hours. If this task becomes automatic, it is very efficient. The automatic planning has two issues. One is much calculation time of electrical circuit simulator, searching billions of electrical conducting paths. The other is interpretation of human fuzzy information, such as ease of work. Deep learning is helpful to resolve them. We performed a model case study of the electrical isolation. We applied a deep neural network (DNN) for dropping in the calculation time. We trained the circuit diagrams and the responses of the circuit simulator to the DNN, constructing an efficient path search algorithm in the DNN. The calculation time of the DNN was shorter by a factor of 32 for the model case, compared with that of the electrical circuit simulator. We applied a deep Q-network (DQN) for the interpretation of fuzzy information. The DQN optimized isolation procedure from the viewpoint of the work load with the equipment layout, related doses, and values of wet bulb globe temperature (WBGT) to prevent heatstroke. (authors)

46 INSTRUMENTATION RELATED TO NUCLEAR SCIENCE AND ↗
NASA NTRSDate not supplied

Reports of Resilient Performance: Investigating Operators' Descriptions of Safety-producing Behaviors in the Aviation Safety Reporting System

While many existing taxonomies and frameworks provide a common vocabulary for describing how human operators fail in the context of sociotechnical systems, at present, there is no common vocabulary to describe how humans succeed. Such a framework would facilitate systematically collecting and analyzing data on how human performance can produce safety, not just how it can reduce safety. One potentially rich source of currently available information for exploring desired performance is the reports submitted to NASA’s Aviation Safety Reporting System (ASRS). These de-identified, confidential, and voluntary narrative reports are submitted by pilots, controllers, ground operators, and others within aviation operations. While these reports are primarily submitted to describe safety risks, incidents, and problems, they also often describe how those risks were mitigated, and provide a window into aspects of everyday work in aviation. These reports can be searched in a variety of ways. This paper describes methods for systematically examining ASRS narratives to understand how operators talk about their own resilient behaviors during adverse safety conditions and events. Guided by Erik Hollnagel’s Resilience Assessment Grid framework (i.e., anticipate, monitor, respond, learn), various approaches and tools for such inquiries are described. The approach, process, challenges, and suggestions to building an operator-based description of resilient performance are discussed, and tools to facilitate data analysis to maximize learning from these reports are described.

ASRS narratives↗
NASA NTRS1996

NASA Mir program: Mission operations concept

The joint NASA/Russian Space Agency mission program is discussed, considering the lessons learned. The initial Shuttle Mir science program and the NASA Mir program are described. The NASA Mir program is organized into ten distinct working groups which are co-chaired by representatives from the two cooperating nations. The NASA component is managed from the Johnson Space Center (TX). The support provided by NASA for long-duration missions and Mir expeditions is described. The scope of the scientific research carried out within the framework of the joint program is considered. The NASA Mir training approach is discussed and the mission operations are reviewed with emphasis on the Mir 21/NASA 2 mission.

Cardenas, Jeffrey A.↗
DOE OSTI2025

A methodology for decay heat characterization in molten salt reactors

Accurate decay heat prediction in molten salt reactors (MSRs) faces dual challenges: complex operational uncertainties and the need for interpretable models compatible with engineering workflows. This work presents a hybrid machine learning and segmented polynomial methodology that addresses both requirements through three key innovations. First, a modular data architecture encodes MSR-specific operational parameters (power density: 1-100 W cm -3 , humidity: 0-0.1 wt %, air ingress: 0-0.1 mol %) with uncertainty-aware temporal discretization spanning 15 orders of magnitude. Second, region-optimized machine learning models achieve 92.3 % root mean square error (RMSE) reduction over conventional polynomials while maintaining physical interpretability through automated piecewise equation generation. Third, dual front-end interfaces accelerate safety analyses — a Jupyter environment enables researchers to explore 10,000+ parameter combinations via interactive widgets, while a Streamlit web application reduces design iteration cycles through production-grade visualization tools. Operational deployment demonstrates prediction times of only a couple hundred milliseconds for 10 4 years decay profiles, enabling real-time optimization of spent fuel container designs.

42 - ENGINEERING↗
DOE OSTI2022

Predictive Modeling of Local Film-Cooling Flow on a Turbine Rotor Blade

Abstract In the turbine section of a modern gas turbine engine, components exposed to the main gas path flow rely on cooling air to maintain hardware durability targets. Therefore, monitoring turbine cooling flow is essential to the diagnostic and prognostic efficacy of a condition-based operation and maintenance (CBOM) approach. This study supports CBOM goals by leveraging supervised machine learning to estimate relative changes to local film-cooling flowrate using surface temperature measured on the pressure side of a rotating turbine blade operating at engine-relevant aerothermal conditions. Throughout the lifetime of a film-cooled turbine component, characteristics of the film-cooling flow—such as film trajectory and cooling effectiveness—vary as degradation-driven geometry distortions occur, which ultimately affects the relationship between the model input and the model output—film-cooling flowrate predictions. The present study addresses this complication by testing a data-driven model on multiple turbine blades of the same nominal design, but with each blade exhibiting different localized film-cooling flow characteristics. By testing the model in this manner, strategies for mitigating the detrimental effects of film-cooling flow characteristic variations on model performance were investigated, and the corresponding flowrate prediction accuracy was quantified.

Engineering↗
DOE OSTI2025

Performance Evaluation of Intelligent Solar Control Software Through Hardware-in-the-Loop (CRADA Final Report)

Recent research has highlighted the potential for solar to act as a zero-marginal-cost and zero-emission flexibility resource on the bulk power system when operated with advanced control systems. To increase the performance of these systems, leading technologies, including machine learning (ML) and hierarchical inverter set point allocation, have been developed by Latimer Controls, Inc. to estimate the headroom of large PV plants for grid operation and control; however, these technologies lack comprehensive validation under real-world application scenarios. Latimer Controls, Inc. received two voucher awards for research at a national laboratory from the Department of Energy American Made Solar Prize Round 6. The National Renewable Energy Laboratory (NREL) was selected to collaborate with Latimer staff to conduct a performance evaluation of Latimer PV control software. The NREL team will develop a hardware-in-the-loop (HIL) testbed to perform testing and validation of the Latimer PV control technology in a de-risked yet realistic testbed environment. Latimer and NREL worked together to analyze the test data, draw conclusions from the results, and disseminate the resulting scientific findings. In this CRADA work, we propose to test and validate the real-world application of the Latimer Control solution in an HIL environment. We evaluate the performance of different flexible solar technologies in responding to automatic generation control signals in a closed-loop fashion. In particular, a data-driven potential high limit (PHL) estimation is developed for large solar plants to accurately estimate their headroom so that they have fast and short-time regulation and control capability to participate in grid services and respond to grid signals in real time (e.g., AGC). This PHL estimation algorithm is embedded in a hardware power plant controller (PPC) and tested with an IEEE-39 bus system model developed in RTDS. To account for the varying cloud conditions and diverse inverter dispatches, we developed a 135-MW PV plant with detailed modeling of 27 individual PV modules and inverters using RTDS. The real-world communications used in such big plants, such as ModBus TCP/IP for inverter level and DNP3 for plant level, were developed to emulate the real-world applications in big PV plants. The ML-based PHL estimation method is tested under nine separate weather scenarios against the ‘reference-control’ solution, hereafter referred to as the baseline solution. The baseline method reserves a subset of inverters (reference group) to operate at their PHL at all times and dispatches only the remaining inverters (control group) at curtailed levels to fulfill the flexibility need. Despite being successfully piloted by NREL in California in 2017 and Chile in 2020, there exist two gaps in the state of the art to fully unlock the flexibility of PV plants: a. There is a trade-off between the PHL estimation accuracy and the flexibility range. b. There lacks granularity in the PHL estimation to capture the variation across inverters. The Latimer solution seeks to address these gaps by applying machine learning methods to improve PHL estimation accuracy while accounting for variability at every inverter. Performance metrics were taken from the 2023 Georgia Power CARES utility-scale RFP. The results demonstrate that the ML-based approach outperforms the traditional baseline method in PHL estimation accuracy for 7 of 9 scenarios. The average PHL error across the nine scenarios was 7.40% for the ML-based method, 2.06% less than the 9.46% PHL error average across scenarios that was exhibited by the baseline method. Additionally, the PHL error was below 5% for at least 95% of the testing interval for 3 of 9 tested intervals with the ML approach, whereas it did not achieve this metric for any of the baseline tests. Overall, simulation results indicate the superior performance of an ML-based approach compared to the conventional baseline reference-control approach, showcasing its potential to support grid stability and operational efficiency. This laboratory HIL testing using real PPC, representative power system simulation models in real-time with detailed PV plant and inverter models, and real-world communication protocols gives us confidence that this machine learning based PHL estimation algorithm works well in the hardware PPC and therefore de-risks future field commissioning. The end goal of this project is to advance grid technology to address the grid operation challenges brought by solar plant’s variability and uncertainties in power generation.

14 SOLAR ENERGY↗
NASA NTRS2022

Simulated Excavation Environment for Lunar Operations

With new pushes to reach and establish long term presences on both the Moon and Mars, significant effort has begun to develop methods of In-Situ Resource Utilization. Many of these methods involve excavation and manipulation of local regolith and, at this time, many of these missions are in the early planning phases. As such, simulations provide both an inexpensive and relatively easy method to perform high level proofs of concept and mission overviews along with an environment to perform machine learning for rovers and other robots. The Simulated Excavation Environment for Lunar Operations (SEELO) was born out of this need for consolidated capabilities. SEELO seeks to provide accurate life mission environments and regolith interaction mechanics while remaining lightweight enough to run in faster than real-time. These combined features allow SEELO to be used for mission planning purposes that offer an environment for lunar robots to perform Machine Learning on moving, digging, and various other activities. Using the Real-Time Development Platform (Unity) to utilize regolith excavation models created by Intelligent Capabilities Enhanced-Regolith Advanced Surface Systems Operations Robot and lunar surface data collected by NASA’s Lunar Reconnaissance Orbiter, SEELO has been able to provide NASA with a tool to plan, train, and even devise lunar missions.

Michael DuPuis↗
DOE OSTI2019

Local Feature Sufficiency Exploration for Predicting Security-constrained Generation Dispatch in Multi-Area Power Systems

Deriving generation dispatch is essential for efficient and secure operation of electric power systems. This is usually achieved by solving a security-constrained optimal power flow(SCOPF) problem, which is by nature non-convex, nonlinear and thus computational intensive. The state-of-the-art optimization approaches are not able to solve this problem for large-scale power systems within power system operation time window (usually 5 minutes). In this work, we developed supervised learning approaches to determine security-constrained generation dispatch within much shorter time window. More importantly, the physical constrain of only accessing to local measurements and other information in most utilities’ real-time operation can not be ignored for the predictive models.The feasibility and accuracy of utilizing only local features(measurements and grid information in one area) to predict optimal local generation dispatch (dispatch of all generators in the corresponding area) in multi-area power systems has been explored. The results showed optimal local generation dispatch can be predicted with local features with high accuracy, which is comparable to the results obtained with global features.

Sun, Yixuan↗
NASA NTRSDate not supplied

ISS Payload Operations Training During the COVID-19 Pandemic: Impacts and Solutions

Introduction: The onset and the protracted duration of the COVID-19 pandemic brought a dramatic and rapid transformation to almost every aspect of humanity in 2020. The world’s space agencies and their missions were not immune to the unpredictable and wide-sweeping changes. One discipline principally affected was mission operations and the various groups supporting that critical function. Mission support teams, especially for complex and crewed missions like the International Space Station (ISS) were forced to rapidly rethink how and where control center staff performed their vital work. Operations training – an essential element to mission ops, had unique hurdles to overcome. Operations training is responsible for preparing astronaut crews for their scientific missions, providing recurring proficiency and currency material to flight controllers, as well as ensuring new team members are ready to join their colleagues on console. Every element of training was impacted by COVID restrictions. From orientation and introductory classes for new controllers, training for scientists and payload developers, to simulations and advanced lessons, critical On the Job Training (OJT) and final evaluations; all aspects faced new challenges. Operations trainers at NASA’s Marshall Space Flight Center (MSFC) in Huntsville, Alabama, were forced to rethink, retool, and become more efficient with trainees and training resources in order to continue supporting payload operations on the ISS. Impacts and Barriers to Operations Training: The pandemic started in the United States in early March 2020. Immediately, NASA mandated that the support for ISS real-time operations was critical. As a result, physical access to the ISS Payload Operations Center was restricted to only those people supporting console operations. Thus, use of on-site NASA facilities and any trainer to trainee face-to-face interaction was not authorized. Trainers and trainees had to quickly shift to 100% remote learning. In the short term, this was not a problem since NASA had already prepared Information Technology (IT) resources that facilitated remote access to mission resources like classes, documents and teleconferences. However, instructors quickly discovered the classes that they were accustomed to delivering in a large classroom environment did not translate well to remote teaching. The lack of non-verbal communication with the class became a major barrier to instruction. Another significant hurdle to operations training was the mandate that all simulations could only be held remotely. The logistics of planning and executing even small simulations proved to be challenging, almost impossible, due to IT technology and public internet limitations. With simulations essentially stopped, as well as the restrictions on most OJT training, trainees were essentially stopped in their advancement towards certification. An additional barrier that had to be overcome was the formal documentation of the curriculum objectives. Even though NASA had been deliberately transitioning to electronic documents for years, some organizations were still relying on “pen and ink” documents to formalize training completion. The logistics of implementing secure and controlled e-signature documents in a standardized, NASA approved format had to be addressed. Lesson Learned and Efficiencies: Once the various limitations were identified, ISS trainers at MSFC discussed, proposed, and prioritized new options and techniques. Transitioning to all electronic learning materials and certifications was a relevantly easy fix. Teaching courses to large and diverse groups took additional shifts in the NASA training paradigm. Likewise, methods and procedures for preparing astronauts for their missions were forced to be revised. Simulation supervisors and their teams were also forced to find more efficient techniques to provide realistic training experience. Communication and approvals from management was essential. In every case, the ISS payload operations instructors found novel and efficient solutions to all functions listed above. This paper will discuss the factors and solutions payloads operations trainers found to keep scientific research on the ISS flying forward to mission success.

ISS Operations↗
NASA NTRS2010

The Evolution of the Rendezvous Profile During the Space Shuttle Program

The rendezvous and proximity operations approach design techniques for space shuttle missions has changed significantly during the life of the program in response to new requirements that were not part of the original mission design. The flexibility of the shuttle onboard systems design and the mission planning process has allowed the program to meet these requirements. The design of the space shuttle and the shift from docking to grappling with a robotic ann prevented use of legacy Apollo rendezvous techniques. Over the life of the shuttle program the rendezvous profile has evolved due to several factors, including lowering propellant consumption and increasing flexibility in mission planning. Many of the spacecraft that the shuttle rendezvoused with had unique requirements that drove the creation of mission-unique proximity operations. The dockings to the Russian Mir space station and International Space Station (ISS) required further evolution of rendezvous and proximity operations techniques and additional sensors to enhance crew situational awareness. After the Columbia accident, a Rendezvous Pitch Maneuver (RPM) was added to allow tile photography from ISS. Lessons learned from these rendezvous design changes are applicable to future vehicle designs and operations concepts.

Summa, William R.↗
DOE OSTI2021

Learning Sequential Distribution System Restoration via Graph-Reinforcement Learning

We report a distribution service restoration algorithm as a fundamental resilient paradigm for system operators provides an optimally coordinated, resilient solution to enhance the restoration performance. The restoration problem is formulated to coordinate distribution generators and controllable switches optimally. A model-based control scheme is usually designed to solve this problem, relying on a precise model and resulting in low scalability. To tackle these limitations, this work proposes a graph-reinforcement learning framework for the restoration problem. We link the power system topology with a graph convolutional network, which captures the complex mechanism of network restoration in power networks and understands the mutual interactions among controllable devices. Latent features over graphical power networks produced by graph convolutional layers are exploited to learn the control policy for network restoration using deep reinforcement learning. The solution scalability is guaranteed by modeling distributed generators as agents in a multi-agent environment and a proper pre-training paradigm. Comparative studies on IEEE 123-node and 8500-node test systems demonstrate the performance of the proposed solution.

24 POWER TRANSMISSION AND DISTRIBUTION↗
DOE OSTI2017

Data analytics and optimization of an ice-based energy storage system for commercial buildings

Ice-based thermal energy storage (TES) systems can shift peak cooling demand and reduce operational energy costs (with time-of-use rates) in commercial buildings. The accurate prediction of the cooling load, and the optimal control strategy for managing the charging and discharging of a TES system, are two critical elements to improving system performance and achieving energy cost savings. This study utilizes data-driven analytics and modeling to holistically understand the operation of an ice–based TES system in a shopping mall, calculating the system’s performance using actual measured data from installed meters and sensors. Results show that there is significant savings potential when the current operating strategy is improved by appropriately scheduling the operation of each piece of equipment of the TES system, as well as by determining the amount of charging and discharging for each day. A novel optimal control strategy, determined by an optimization algorithm of Sequential Quadratic Programming, was developed to minimize the TES system’s operating costs. Three heuristic strategies were also investigated for comparison with our proposed strategy, and the results demonstrate the superiority of our method to the heuristic strategies in terms of total energy cost savings. Specifically, the optimal strategy yields energy costs of up to 11.3% per day and 9.3% per month compared with current operational strategies. A one-day-ahead hourly load prediction was also developed using machine learning algorithms, which facilitates the adoption of the developed data analytics and optimization of the control strategy in a real TES system operation.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗
NASA NTRSDate not supplied

SPHINX: An SEP Model Validation Infrastructure developed through Community Challenges and the SEP Scoreboards

Solar Energetic Particle (SEP) events are interesting from a scientific perspective as they are the product of a broad set of physical processes from the corona out through the extent of the heliosphere, and provide insight into processes of particle acceleration and transport that are widely applicable in astrophysics. From the operations perspective, SEP events pose a radiation hazard for aviation, electronics in space, and human space exploration, in particular for missions outside of the Earth’s protective magnetosphere including to the Moon and Mars (Whitman et al 2022). For these reasons, SEP modelers have developed a rich and diverse set of models with a wide variety of aims. Some models probe the basic physics at the heart of particle acceleration and transport. Others produce fast statistical forecasts or employ disruptive new techniques like Machine Learning with the goal to assist end users in making operational decisions. To enable a consistent and quantitative understanding of SEP model performance, a generalized, automated validation infrastructure, called SPHINX, is being developed at NASA SRAG in close collaboration with NASA CCMC, NASA M2M, NOAA SWPC, and BIRA-IASB. This infrastructure has been built up through a multi-year community challenge. Starting in 2018 at the SHINE workshop, an effort was launched through SHINE, ISWAT, and ESWW to encourage quantitative, comprehensive, and consistent validation of SEP models. This effort has defined a set of challenge SEP events with the aim of generating quantitative comparisons between forecasts and observations and a set of challenge “non-events” to assess false alarms. In 2023, these challenge lists have been extended to statistically significant numbers with a prescribed set of rules for producing forecasts and supported through the dedicated SEPVAL working meetings. The participation of the research community has allowed the infrastructure to validate all the types of outputs being produced by SEP models. In parallel, the SPHINX code is being applied to real time forecasts submitted to the SEP Scoreboards, ensuring that the validation infrastructure can interpret forecasts produced in an operational scenario and provide metrics meaningful for operations. Upon completion, SPHINX and its interactive user interface, SPHINX-Web, will be made available for public use.

space weather↗
DOE OSTI2023

Spatio-Temporal Deep Graph Network for Event Detection, Localization, and Classification in Cyber-Physical Electric Distribution System

This work proposes a deep graph learning framework to identify, locate, and classify power, cyber, and cyber power events at the distribution system level. The proposed algorithm jointly exploits spatial, temporal, and node-level cyber and physical data features. The developed graph neural network, together with a deep autoencoder, utilizes physical measurements from distribution level phasor measurement units and cyber data from communication network logs. The spatial structure of the synchrophasor measurements and network is incorporated through a weighted adjacency matrix. The temporal structure is incorporated by defining a spatial operation in the gated recurrent unit. This spatio-temporal learning element resides inside a power event detection, localization, and classification module that provides the degree of confidence for an event label. To accurately pinpoint the location of an event to the nearest bus equipped with a measurement unit, a combination of squared error and proximity score is utilized. Also included is a cyber event detection module that employs heteroskedasticity to analyze the significance of various cyber features during different types of attacks. Finally, a dual-bit cyber-power decision table determines the nature of the event. The proposed method is validated on two distribution systems modeled in OPAL-RT/Hypersim with limited phasor measurement units for different possible physical and cyber events. Further analyses include comparison with other state-of-the-art methods and validation in the presence of measurement noise. As a result, our method outperforms existing approaches and achieves an average detection accuracy of 97.97%, F1-score of 96.88%, precision of 96.53%, and recall of 98.57%.

24 POWER TRANSMISSION AND DISTRIBUTION↗
NASA NTRS1990

Learning-based position control of a closed-kinematic chain robot end-effector

A trajectory control scheme whose design is based on learning theory, for a six-degree-of-freedom (DOF) robot end-effector built to study robotic assembly of NASA hardwares in space is presented. The control scheme consists of two control systems: the feedback control system and the learning control system. The feedback control system is designed using the concept of linearization about a selected operating point, and the method of pole placement so that the closed-loop linearized system is stabilized. The learning control scheme consisting of PD-type learning controllers, provides additional inputs to improve the end-effector performance after each trial. Experimental studies performed on a 2 DOF end-effector built at CUA, for three tracking cases show that actual trajectories approach desired trajectories as the number of trials increases. The tracking errors are substantially reduced after only five trials.

Nguyen, Charles C.↗
NASA NTRS2018

Lessons Learned in the Flight Qualification of the S-NPP and NOAA-20 Solar Array Mechanisms

Deployable solar arrays are the energy source used on almost all Earth orbiting spacecraft and their release and deployment are mission-critical; fully testing them on the ground is a challenging endeavor. The 8 meter long deployable arrays flown on two sequential NASA weather satellites were each comprised of three rigid panels almost 2 meters wide. These large panels were deployed by hinges comprised of stacked constant force springs, eddy current dampers, and were restrained through launch by a set of four releasable hold-downs using shape memory alloy release devices. The ground qualification testing of such unwieldy deployable solar arrays, whose design was optimized for orbital operations, proved to be quite challenging and provides numerous lessons learned. A paperwork review and follow-up inspection after hardware storage determined that there were negative torque margins and missing lubricant, this paper will explain how these unexpected issues were overcome. The paper will also provide details on how the hinge subassemblies, the fully-assembled array, and mechanical ground support equipment were subsequently improved and qualified for a follow-on flight with considerably less difficulty. The solar arrays built by Ball Aerospace Corp. for the Suomi National Polar Partnership (S-NPP) satellite and the Joint Polar Satellite System (JPSS-1) satellite (now NOAA-20) were both successfully deployed on-obit and are performing well.

Helfrich, Daniel↗
NASA NTRS2018

Lessons Learned in the Flight Qualification of the S-NPP and NOAA-20 Solar Array Mechanisms

Deployable solar arrays are the energy source used on almost all Earth orbiting spacecraft and their release and deployment are mission-critical; fully testing them on the ground is a challenging endeavor. The 8 meter long deployable arrays flown on two sequential NASA weather satellites were each comprised of three rigid panels almost 2 meters wide. These large panels were deployed by hinges comprised of stacked constant force springs, eddy current dampers, and were restrained through launch by a set of four releasable hold-downs using shape memory alloy release devices. The ground qualification testing of such unwieldy deployable solar arrays, whose design was optimized for orbital operations, proved to be quite challenging and provides numerous lessons learned. A paperwork review and follow-up inspection after hardware storage determined that there were negative torque margins and missing lubricant, this paper will explain how these unexpected issues were overcome. The paper will also provide details on how the hinge subassemblies, the fully-assembled array, and mechanical ground support equipment were subsequently improved and qualified for a follow-on flight with considerably less difficulty. The solar arrays built by Ball Aerospace Corp. for the Suomi National Polar Partnership (SNPP) satellite and the Joint Polar Satellite System (JPSS-1) satellite (now NOAA-20) were both successfully deployed on-obit and are performing well.

Sexton, Adam↗