Research and development techniques for fabrication of lightweight solar concentrators addendum report
Fabrication of copper and nickel solar concentrators
SOLAR COLLECTOR↗
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Integrated Solar Concentrator and Shielded Radiator
A shielded radiator is integrated within a solar concentrator for applications that require protection from high ambient temperatures with little convective heat transfer. This innovation uses a reflective surface to deflect ambient thermal radiation, shielding the radiator. The interior of the shield is also reflective to provide a view factor to deep space. A key feature of the shield is the parabolic shape that focuses incoming solar radiation to a line above the radiator along the length of the trough. This keeps the solar energy from adding to the radiator load. By placing solar cells along this focal line, the concentration of solar energy reduces the number and mass of required cells. By shielding the radiator, the effective reject temperature is much lower, allowing lower radiator temperatures. This is particularly important for lower-temperature processes, like habitat heat rejection and fuel cell operations where a high radiator temperature is not feasible. Adding the solar cells in the focal line uses the concentrating effect of the shield to advantage to accomplish two processes with a single device. This shield can be a deployable, lightweight Mylar structure for compact transport.
Clark, David Larry↗
A transmittance-optimized, point-focus Fresnel lens solar concentrator
The development of a point-focus Fresnel lens solar concentrator for high-temperature solar thermal energy system applications is discussed. The concentrator utilizes a transmittance-optimized, short-focal-length, dome-shaped refractive Fresnel lens as the optical element. This concentrator combines both good optical performance and a large tolerance for manufacturing, deflection, and tracking errors. The conceptual design of an 11-meter diameter concentrator which should provide an overall collector efficiency of about 70% at an 815 C (1500 F) receiver operating temperature and a 1500X geometric concentration ratio (lens aperture area/receiver aperture area) was completed. Results of optical and thermal analyses of the collector, a discussion of manufacturing methods for making the large lens, and an update on the current status and future plans of the development program are included.
Oneill, M. J.↗
A Transmittance-optimized, Point-focus Fresnel Lens Solar Concentrator
The development of a point-focus Fresnel lens solar concentrator for high-temperature solar thermal energy system applications is discussed. The concentrator utilizes a transmittance-optimized, short-focal-length, dome-shaped refractive Fresnel lens as the optical element. This concentrator combines both good optical performance and a large tolerance for manufacturing, deflection, and tracking errors. The conceptual design of an 11-meter diameter concentrator which should provide an overall collector efficiency of about 70% at an 815 C (1500 F) receiver operating temperature and a 1500X geometric concentration ratio (lens aperture area/receiver aperture area) was completed. Results of optical and thermal analyses of the collector, a discussion of manufacturing methods for making the large lens, and an update on the current status and future plans of the development program are included.
Oneill, M. J.↗
Solar concentrator technology development for space based applications, volume 1
Thermoelectric conversion using a radio-isotope heat source has been used where outer planetary space craft are too far away for absorbing significant solar energy. Solar dynamic power (SDP) conversion is one technology that offers advantages for applications within the inner planet region. Since SDP conversion efficiency can be 2 to 3 times higher than photovoltaic, the collecting surfaces are much reduced in area and therefore lighter. This becomes an advantage in allocating more weight to launched payloads. A second advantage results for low earth orbit applications. The reduced area results in lower drag forces on the spacecraft and requires less reboost propellant to maintain orbit. A third advantage occurs because of the sun-to-shade cycling while in earth orbit. Photovoltaic systems require batteries to store energy for use when in the shade, and battery life for periods of 10 to 15 years is not presently achievable. For these reasons the Solar Dynamics and Thermal Systems Branch at NASA LeRC has funded work in developing SDP systems. The generic SDP system uses a large parabolic solar concentrator to focus solar energy onto a power conversion device. The concentrators are large areas and must therefore be efficient and have low specific weights. Yet these surfaces must be precise and capable of being stowed in a launch vehicle and then deployed and sometimes unfurled in space. There are significant technical challenges in engineering such structures, and considerable investigation has been made to date. This is the first of two volumes reporting on the research done by the Advanced Manufacturing Center at Cleveland State University to assist NASA LeRC in evaluating this technology. The objective of the grant was to restore the solar concentrator development technology of the 1960s while improving it with advances that have occurred since then. This report summarizes the work done from January 1989 through December 1991.
Pintz, A.↗
Solar concentrator technology development for space based applications, volume 2
Thermoelectric conversion using a radio-isotope heat source has been used where outer planetary space craft are too far away for absorbing significant solar energy. Solar dynamic power (SDP) conversion is one technology that offers advantages for applications within the inner planet region. Since SDP conversion efficiency can be 2 to 3 times higher than photovoltaic, the collecting surfaces are much reduced in area and therefore lighter. This becomes an advantage in allocating more weight to launched payloads. A second advantage results for low earth orbit applications. The reduced area results in lower drag forces on the spacecraft and requires less reboost propellant to maintain orbit. A third advantage occurs because of the sun-to-shade cycling while in earth orbit. Photovoltaic systems require batteries to store energy for use when in the shade, and battery life for periods of 10 to 15 years is not presently achievable. For these reasons the Solar Dynamics and Thermal Systems Branch at NASA LeRC has funded work in developing SDP systems. The generic SDP system uses a large parabolic solar concentrator to focus solar energy onto a power conversion device. The concentrators are large areas and must therefore be efficient and have low specific weights. Yet these surfaces must be precise and capable of being stowed in a launch vehicle and then deployed and sometimes unfurled in space. There are significant technical challenges in engineering such structures, and considerable investigation has been made to date. This is the second of two volumes reporting on the research done by the Advanced Manufacturing Center at Cleveland State University to assist NASA LeRC in evaluating this technology. This volume includes the appendices of selected data sets, drawings, and procedures. The objective of the grant was to restore the solar concentrator development technology of the 1960s while improving it with advances that have occurred since then. This report summarizes the work done from January 1989 through December 1991.
Pintz, A.↗
FABRICATION AND EXPERIMENTAL EVALUATION OF LIGHT-WEIGHT SOLAR CONCENTRATORS
Fabrication and experimental evaluation of light- weight solar concentrators
ENERGY CONVERSION EFFICIENCY↗
The systems impact of a concentrated solar array on a Jupiter orbiter
Results of a study are presented suggesting that a Galileo Jupiter orbiting mission could be performed with a concentrated solar array power source. A baseline spacecraft design using concentrated arrays is given, and the overall spacecraft implications for attitude control, propulsion, power conditioning and the resultant spacecraft mass are examined. It is noted that while the concentrated array concept still requires extensive development effort, no insurmountable system level barriers preclude the use of a concentrated solar array on this difficult mission, with its stressing radiation environment, its lengthy periods of spacecraft shadowing as it passes behind Jupiter, and, finally, its large delta v burn required for orbital insertion.
Rockey, D. E.↗
Protective telescoping shield for solar concentrator
An apparatus is described for use with a solar concentrator such as a parabolic dish which concentrates sunlight onto a small opening of a solar receiver, for protecting the receiver in the event of a system failure that could cause concentrated sunlight to damage the receiver. The protective apparatus includes a structure which can be moved to a stowed position where it does not block sunlight, to a deployed position. In this position, the structure forms a tube which substantially completely surrounds an axis connecting the receiver opening to the center of the concentrator at locations between the receiver and the concentrator.
Argoud, M. J.↗
Solar concentrator advanced development project
A solar dynamic concentrator design developed for use with a solar-thermodynamic power generation module intended for the Space Station is considered. The truss hexagonal panel reflector uses a modular design approach and is flexible in attainable flux profiles and assembly techniques. Preliminary structural, thermal, and optical analysis results are discussed. Accuracy of the surface reflectors should be within 5 mrad rms slope error, resulting in the need for close fabrication tolerances. Significant fabrication issues to be addressed include the facet reflective and protective coating processes and the surface specularity requirements.
Corrigan, Robert D.↗
Cassegrainian concentrator solar array exploratory development module
A miniaturized Cassegrainian concentrator solar array concept is under development to reduce the cost of multi-kW spacecraft solar arrays. A primary parabolic reflector directs incoming solar energy to a secondary, centrally mounted inverted hyperbolic reflector and down onto a solar cell mounted on an Mo heat spreader on a 0.25 mm thick Al heat fin. Each unit is 12.7 mm thick, which makes the concentrator assembly roughly as thick as a conventional panel. The output is 100 W/sq and 20 W/kg, considering 20% efficient Si cells at 100 suns. A tertiary light catcher is mounted around the cell to ameliorate optic errors. The primary reflector is electroformed Ni with protective and reflective coatings. The cells have back surface reflectors and a SiO antireflective coating. An optical efficiency of 80% is projected, and GaAs cells are being considered in an attempt to raise cell efficiencies to over 30%.
Patterson, R. E.↗
Solar concentration by curved-base Fresnel lenses
The solar concentration performance of idealized curved base line focusing Fresnel lenses is analyzed. A simple optical model was introduced to study the effects of base curvature and lens f-number. Thin lens ray tracing and the laws of reflection and refraction are used to develop expression for lens transmittance and image plane intensity profiles. The intensity distribution over the solar spectrum, lens dispersion effects, and absorption by the lens material are included in the analysis. Model capabilities include assessment of lens performance in the presence of small transverse tracking errors and the sensitivity of solar image characteristics to focusing.
Cosby, R. M.↗
Offset paraboloidal solar concentrator
Section of conventional paraboloid, offset from its major axis, is used as reflector in solar concentrator. Design increases solar gathering efficiency by 3 to 4 percent by eliminating shadowing and blocking of solar rays. In addition, reflector can be folded toward receiver, reducing wind-loading and making maintenance easier.
Chow, E. Y.↗
Advanced solar concentrator mass production, operation, and maintenance cost assessment
The object of this assessment was to estimate the costs of the preliminary design at: production rates of 100 to 1,000,000 concentrators per year; concentrators per aperture diameters of 5, 10, 11, and 15 meters; and various receiver/power conversion package weights. The design of the cellular glass substrate Advanced Solar Concentrator is presented. The concentrator is an 11 meter diameter, two axis tracking, parabolic dish solar concentrator. The reflective surface of this design consists of inner and outer groups of mirror glass/cellular glass gores.
Niemeyer, W. A.↗
Design, performance investigation and delivery of a miniaturized Cassegrainian concentrator solar array
A miniaturized Cassegrainian concentrator (MCC) solar array concept is being developed with the objective of significantly reducing the recurring cost of multikilowatt solar arrays. The desired cost reduction is obtained as a result of using very small high efficiency solar cells in conjunction with low-cost optics. In the MCC single element concept and panel concept, incident solar radiation is reflected from a primary parabolic reflector to a secondary hyperbolic reflector and finally to a 4-millimetr diameter solar cell. A light catcher cone is used to improve off-axis performance. An element is approximately 13-millimeters thick which permits efficient launch stowage of the concentrator system panels without complex optical component deployments or retractions. The MCC elements are packed in bays within graphite epoxy frames and are electrically connected into appropriate series-parallel circuits. A MCC single element with a 21 sq cm entrance aperture and a 20 percent efficient, 0.25 sq cm gallium arsenide solar cell has the same power output as 30-sq cm of 11-percent efficiency (at 68 C) silicon solar cells. The MCC concept provides the potential for a significant reduction in array cost due to a 99 percent reduction in required cell area and a 30 percent reduction in array area relative to planar array of equivalent power.
Patterson, R. E.↗
Large all-metal solar concentrators for space power systems
Large all-metal solar concentrators for space power systems
SOLAR POWER SYSTEM↗
Implementation Concept of Operation for a Multi-Purpose Cassegrain Solar Concentrator, Micro-Spectrometers, and Electrostatic Neutralizers to Enable In Situ Construction Activities plus Lunar, Planetary, and Deep Space Science Exploration on the Moon
The ability to utilize regolith would support human missions to the Moon and Mars by both stabilizing the surface as well as the use of indigenous resources. Precision landing requirements include surface stabilization to prevent damage or contamination due to regolith projectiles as a result of plume interaction with regolith. The use of indigenous resources rather than hauling materials from Earth appears to be economically a palatable option by converting indigenous resources to usable products. However, such activities have new technical challenges to overcome the issues related to lunar environmental conditions, a wide range of temperature fluctuation, extremely high vacuum, and electrostatically charged fine regolith dusts. For both the regolith sintering and extraction of resources onsite, a Cassegrain solar concentrator was studied for not only sintering lunar regolith into a hardened stabilized surface, but also other multiple applications. This report illustrates a Cassegrain solar concentrator that has multi-functional capabilities for space missions. Proper design and implementation of high-performance lightweight composite materials for the primary mirror of the Cassegrain concentrator can offer multiple capabilities to be performed on the Moon. The multiple applications studied with Cassegrain concentrators are (1) Solar sintering for landing pad and habitats, (2) Harvest of volatiles: H2O, O2, H2, and He-3, (3) Space antenna for telemetry and telecommunication, and (4) Space telescope with 20-meter aperture that exceeds the space telescopes to date in terms of the State-of-Art (SOA) in resolution and aperture diameter. In this study, a key emphasis was placed on the NASA Langley-developed boron nitride nanotube (BNNT) nanocomposite technology which is ideal for the segmented primary mirror structure of the Cassegrain system because it promises a very low coefficient of thermal expansion (CTE) and negligible Poisson ratio. Also, BNNT nanocomposites offer several noticeable benefits, such as light weight, radiation shielding capability, and mechanical strength for structural applications. Additionally, the NASA Langley-developed bullet-like micro-spectrometer and electrostatic power generator were reviewed for mineral mapping applications and electrostatic power generation and dust mitigation from electrostatically charged regolith.
landing pad↗
Out-of-Focus Alinement of Solar Concentrators
In new alinement technique, no attempt made to simulate infinitely distant light source, and all mirrors left uncovered throughout procedure. Light source placed at distance of 1,650 feet (503 m); other distances used. Alinement of approximately 250 mirror facets of paraboloidal solar concentrator simplified by precalculated images reflected from all facets. Developed for large solar concentrators, technique used with other multiplemirror or multiple-light-source systems for producing specified illuminance patterns.
Argoud, M. J.↗