Deployable large area solar array structure Final design report
Prototype deployable large area solar array structure design
SOLAR CELL↗
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Solar Array Structures for 300 kW-Class Spacecraft
State-of-the-art solar arrays for spacecraft provide on the order of 20 kW of electrical power, and they usually consist of 3J solar cells bonded to hinged rigid panels about 1 inch in thickness. This structural construction allows specific mass and packaging volumes of up to approximately 70 W/kg and 15 kW/m3 to be achieved. Significant advances in solar array structures are required for future very-high-power spacecraft (300+ kW), such as those proposed for pre-positioning heavy cargo on or near the Moon, Mars, or asteroids using solar electric propulsion. These applications will require considerable increases in both W/kg and kW/m3, and will undoubtedly require the use of flexible-substrate designs. This presentation summarizes work sponsored by NASA's Game Changing Development Program since Oct. 2011 to address the challenge of developing 300+ kW solar arrays. The work is primarily being done at NASA Langley, NASA Glenn, and two contractor teams (ATK and DSS), with technical collaboration from AFRL/Kirtland. The near-tem objective of the project is design, analysis, and testing of 30-50 kW solar array designs that are extensible to the far-term objective of 300+ kW. The work is currently focused on three designs: the MegaFlex concept by ATK, the Mega-ROSA concept by DSS, and an in-house 300-kW Government Reference Array concept. Each of these designs will be described in the presentation. Results obtained to date by the team, as well as future work plans, for the design, analysis, and testing of these large solar array structures will be summarized.
Pappa, Richard↗
Deployable large area solar array structure Preliminary developmental report, phase I
Roller drum, actuation system, support structure, electrical provisions, and substrate design concepts for deployable large area solar array structure
ACTUATOR↗
Preliminary space station solar array structural design study
Structurally efficient ways to support the large solar arrays (3,716 square meters which are currently considered for space station use) are examined. An erectable truss concept is presented for the on orbit construction of winged solar arrays. The means for future growth, maintenance, and repair are integrally designed into this concept. Results from parametric studies, which highlight the physical and structural differences between various configuration options are presented. Consideration is given to both solar blanket and hard panel arrays.
Dorsey, J. T.↗
Low concentration ratio solar array structural configuration
The design and structural properties of a low concentration ratio solar array are discussed. The assembled module consists of six interconnected containers which are compactly stowed in a volume of 3.24 m(3) for delivery to orbit by the shuttle. The containers deploy in accordian fashion into a rectangular area of 19.4 x 68 meters and can be attached to the user spacecraft along the longitudinal centerline of the end container housing. Five rotary incremental actuators requiring about 8 watts each will execute the 180-degree rotation at each joint. Deployable masts (three per side) are used to extend endcaps from the housing in both directions. Each direction is extended by three masts requiring about 780 watts for about 27 minutes. Concentrator elements are extended by the endcaps and are supported by cable systems that are connected between the housings and endcaps. These power generating elements contain reflector panels which concentrate light onto the solar panels consisting of an aluminum radiator with solar cells positioned within the element base formed by the reflectors. A flat wire harness collects the power output of individual elements for transfer to the module container housing harnesses.
Nalbandian, S. J.↗
Systems Engineering Lessons Learned from Solar Array Structures and Mechanisms Deployment
This report has been developed by the National Aeronautics and Space Administration (NASA) Human Exploration and Operations Mission Directorate (HEOMD) Risk Management team in close coordination with the Engineering Directorate at LaRC. This document provides a point-in-time, cumulative, summary of actionable key lessons learned derived from the design project. Lessons learned invariably address challenges and risks and the way in which these areas have been addressed. Accordingly the risk management thread is woven throughout the document.
Solar Array Structures↗
Input Shaping to Reduce Solar Array Structural Vibrations
Structural vibrations induced by actuators can be minimized using input shaping. Input shaping is a feedforward method in which actuator commands are convolved with shaping functions to yield a shaped set of commands. These commands are designed to perform the maneuver while minimizing the residual structural vibration. In this report, input shaping is extended to stepper motor actuators. As a demonstration, an input-shaping technique based on pole-zero cancellation was used to modify the Solar Array Drive Assembly (SADA) actuator commands for the Lewis satellite. A series of impulses were calculated as the ideal SADA output for vibration control. These impulses were then discretized for use by the SADA stepper motor actuator and simulated actuator outputs were used to calculate the structural response. The effectiveness of input shaping is limited by the accuracy of the knowledge of the modal frequencies. Assuming perfect knowledge resulted in significant vibration reduction. Errors of 10% in the modal frequencies caused notably higher levels of vibration. Controller robustness was improved by incorporating additional zeros in the shaping function. The additional zeros did not require increased performance from the actuator. Despite the identification errors, the resulting feedforward controller reduced residual vibrations to the level of the exactly modeled input shaper and well below the baseline cases. These results could be easily applied to many other vibration-sensitive applications involving stepper motor actuators.
Doherty, Michael J.↗
Efficient structures for geosynchronous spacecraft solar arrays
Structural concepts for deploying and supporting lightweight solar array blankets for geosynchronous electrical powr are evaluated. First, the requirements for more mass efficient solar arrays is established by describing future needs. Then analytical results are set forth which show that not only must lighter weight blankets be developed but also the supporting structure must be improved proportionately. The SEPS configuration is taken to be the state of the art point of departure for improved structural concepts. Several directions for improvement are indicated.
Hedgepeth, J. M.↗
Low-cost solar array structure development
Early studies of flat-plate arrays have projected costs on the order of $50/square meter for installed array support structures. This report describes an optimized low-cost frame-truss structure that is estimated to cost below $25/square meter, including all markups, shipping an installation. The structure utilizes a planar frame made of members formed from light-gauge galvanized steel sheet and is supposed in the field by treated-wood trusses that are partially buried in trenches. The buried trusses use the overburden soil to carry uplift wind loads and thus to obviate reinforced-concrete foundations. Details of the concept, including design rationale, fabrication and assembly experience, structural testing and fabrication drawings are included.
Wilson, A. H.↗
Structural design experience on beryllium solar array
Structural design experience in developing large area Be solar array for Mars flyby mission, describing configurations, requirements, material and manufacturing
Mcafee, F. W.↗
Structural analysis and design of a large area solar array.
Structural analysis and design of large area solar array, noting factors such as temperature distribution, dynamics, internal loads, permissible weight, etc
STRUCTURAL DESIGN↗
Hypervelocity impact facility for simulating materials exposure to impact by space debris
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.
Rose, M. F.↗
Structural scaling approximations for solar arrays
General scaling rules for a photovoltaic array structure are required in order to compare the effectiveness of different cell technologies. Important evaluation criteria for an array are moment of inertia, resonant frequency of vibrational modes, stiffness against acceleration, and resistance losses in the wiring. Approximate scaling relationships for these parameters for a generic solar array structure are presented.
Landis, Geoffrey A.↗
A structural view of solar array developments.
Spacecraft structural criteria for lightweight photovoltaic solar arrays development, discussing Mariner type panel designs and power-to-weight ratios
SPACECRAFT STRUCTURE↗
NASA Office of Aeronautical and Space Technology Summer Workshop. Volume 6: Structures and dynamics panel
Structural requirements for future space missions were defined in relation to technology needs and payloads. Specific areas examined include: large area space structures (antennas, solar array structures, and platforms); a long, slender structure or boom used to support large objects from the shuttle or hold two bodies apart in space; and advanced composite structures for cost effective weight reductions. Other topics discussed include: minimum gage concepts, high temperature components, load and response determination and control, and reliability and life prediction.
Source record↗
Promising Results from Three NASA SBIR Solar Array Technology Development Programs
Results from three NASA SBIR solar array technology programs are presented. The programs discussed are: 1) Thin Film Photovoltaic UltraFlex Solar Array; 2) Low Cost/Mass Electrostatically Clean Solar Array (ESCA); and 3) Stretched Lens Array SquareRigger (SLASR). The purpose of the Thin Film UltraFlex (TFUF) Program is to mature and validate the use of advanced flexible thin film photovoltaics blankets as the electrical subsystem element within an UltraFlex solar array structural system. In this program operational prototype flexible array segments, using United Solar amorphous silicon cells, are being manufactured and tested for the flight qualified UltraFlex structure. In addition, large size (e.g. 10 kW GEO) TFUF wing systems are being designed and analyzed. Thermal cycle and electrical test and analysis results from the TFUF program are presented. The purpose of the second program entitled, Low Cost/Mass Electrostatically Clean Solar Array (ESCA) System, is to develop an Electrostatically Clean Solar Array meeting NASA s design requirements and ready this technology for commercialization and use on the NASA MMS and GED missions. The ESCA designs developed use flight proven materials and processes to create a ESCA system that yields low cost, low mass, high reliability, high power density, and is adaptable to any cell type and coverglass thickness. All program objectives, which included developing specifications, creating ESCA concepts, concept analysis and trade studies, producing detailed designs of the most promising ESCA treatments, manufacturing ESCA demonstration panels, and LEO (2,000 cycles) and GEO (1,350 cycles) thermal cycling testing of the down-selected designs were successfully achieved. The purpose of the third program entitled, "High Power Platform for the Stretched Lens Array," is to develop an extremely lightweight, high efficiency, high power, high voltage, and low stowed volume solar array suitable for very high power (multi-kW to MW) applications. These objectives are achieved by combining two cutting edge technologies, the SquareRigger solar array structure and the Stretched Lens Array (SLA). The SLA SquareRigger solar array is termed SLASR. All program objectives, which included developing specifications, creating preliminary designs for a near-term SLASR, detailed structural, mass, power, and sizing analyses, fabrication and power testing of a functional flight-like SLASR solar blanket, were successfully achieved.
Eskenazi, Mike↗
Static stability of the Space Station solar array FASTMast structure
The combined loads test of the 3-Bay FASTMast marks the end of the Lewis Research Center (LeRC) effort to characterize the behavior of the principal Space Station solar array support structure. The primary objective of this test and analysis effort was to develop a method to predict structural stability failure modes under flight-like applied loads. Included at the beginning of this report is a brief historical perspective of the hardware design development and FASTMast structural stability problem evolution. Once an understanding of the solution process has been established, test and analysis details are presented and related to the postulated failure theories. The combined load test series subjected the structure to a combination of transverse, moment, and torsion loads similar to that expected in the service environment. Nonlinear finite element (FE) models were developed and large displacement analyses were performed to support the test effort and failure mode predictions. Details of the test configuration as well as test and analysis results are presented. The results were then critiqued to establish valid and successful support of the failure mode assessments. Finally, study conclusions are drawn and recommendations for safe operation of the FASTMast structure are presented for consideration.
Shaker, John F.↗