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All sourcesNASA NTRSDOE OSTI
NASA NTRS2019

Structural Analysis Methods for the Roll-Out Solar Array Flight Experiment

The Roll-Out Solar Array (ROSA) flight experiment was launched to the International Space Station (ISS) on June 3rd, 2017. ROSA is an innovative, lightweight solar array with a flexible substrate that makes use of the stored strain energy in its composite structural members to provide deployment without the use of motors. This paper discusses the effort to model the structural dynamics of ROSA using finite element modeling. Two distinct and agnostic approaches were used by separate teams to assess the structural dynamics of the solar array prior to ground vibrational testing and flight testing. Results from each approach are compared to measured dynamics from accelerometers and photogrammetry data gathered on orbit. Advantages and disadvantages of each approach are discussed as are preliminary efforts to calibrate the models to the empirical data for the benefit of future modeling efforts on similar space structures.

Chamberlain, Matthew K.↗
NASA NTRS1996

STS-74/Mir photogrammetric appendage structural dynamics experiment

The Photogrammetric Appendage Structural Dynamics Experiment (PASDE) is an International Space Station (ISS) Phase-1 risk mitigation experiment. Phase-1 experiments are performed during docking missions of the U.S. Space Shuttle to the Russian Space Station Mir. The purpose of the experiment is to demonstrate the use of photogrammetric techniques for determination of structural dynamic mode parameters of solar arrays and other spacecraft appendages. Photogrammetric techniques are a low cost alternative to appendage mounted accelerometers for the ISS program. The objective of the first flight of PASDE, on STS-74 in November 1995, was to obtain video images of Mir Kvant-2 solar array response to various structural dynamic excitation events. More than 113 minutes of high quality structural response video data was collected during the mission. The PASDE experiment hardware consisted of three instruments each containing two video cameras, two video tape recorders, a modified video signal time inserter, and associated avionics boxes. The instruments were designed, fabricated, and tested at the NASA Langley Research Center in eight months. The flight hardware was integrated into standard Hitchhiker canisters at the NASA Goddard Space Flight Center and then installed into the Space Shuttle cargo bay in locations selected to achieve good video coverage and photogrammetric geometry.

Welch, Sharon S.↗
NASA NTRS2012

International Space Station 2A Array Modal Analysis

On December 9th 2009, the International Space Station (ISS) 2A solar array mast experienced prolonged longeron shadowing during a Soyuz undocking. Analytical reconstruction of induced thermal and dynamic structural loads showed an exceedance of the mast buckling limit. Possible structural damage to the solar array mast could have occurred during this event. A Low fidelity video survey of the 2A mast showed no obvious damage of the mast longerons or battens. The decision was made to conduct an on-orbit dynamic test of the 2A array on December 18th, 2009. The test included thruster pluming on the array while photogrammetry data was recorded. The test was similar to other Dedicated Thruster Firings (DTFs) that were performed to measure structural frequency and damping of a solar array. Results of the DTF indicated lower frequency mast modes than model predictions, thus leading to speculation of mast damage. A detailed nonlinear analysis was performed on the 2A array model to assess possible solutions to modal differences. The setup of the parametric nonlinear trade study included the use of a detailed array model and the reduced mass and stiffness matrices of the entire ISS being applied to the array interface. The study revealed that the array attachment structure is nonlinear and thus was the source of error in the model prediction of mast modes. In addition, a detailed study was performed to determine mast mode sensitivity to mast longeron damage. This sensitivity study was performed to assess if the ISS program has sufficient instrumentation for mast damage detection.

Laible, Michael↗
NASA NTRS1985

STACBEAM 2

An investigation being conducted by Astro Aerospace Corporation (Astro) for Jet Propulsion Laboratory in which efficient structures for geosynchronous spacecraft solar arrays are being developed is discussed. Recent developments in solar blanket technology, including the introduction of ultrathin (50 micrometer) silicon solar cells with conversion efficiencies approaching 15 percent, have resulted in a significant increase in blanket specific power. System specific power depends not only on blanket mass but also on the masses of the support structure and deployment mechanism. These masses must clearly be reduced, not only to minimize launch weight, but also to increase array natural frequency. The solar array system natural frequency should be kept high in order to reduce the demands on the attitude control system. This goal is approached by decreasing system mass, by increasing structural stiffness, and by partitioning the blanket. As a result of this work, a highly efficient structure for deploying a solar array was developed.

Adams, L. R.↗
NASA NTRS2016

Structural Design Considerations for a 50 kW-Class Solar Array for NASA's Asteroid Redirect Mission

NASA is planning an Asteroid Redirect Mission (ARM) to take place in the 2020s. To enable this multi-year mission, a 40 kW class solar electric propulsion (SEP) system powered by an advanced 50 kW class solar array will be required. Powered by the SEP module (SEPM), the ARM vehicle will travel to a large near-Earth asteroid, descend to its surface, capture a multi-metric ton (t) asteroid boulder, ascend from the surface and return to the Earth-moon system to ultimately place the ARM vehicle and its captured asteroid boulder into a stable distant orbit. During the years that follow, astronauts flying in the Orion multipurpose crew vehicle (MPCV) will dock with the ARM vehicle and conduct extra-vehicular activity (EVA) operations to explore and sample the asteroid boulder. This paper will review the top structural design considerations to successfully implement this 50 kW class solar array that must meet unprecedented performance levels. These considerations include beyond state-of-the-art metrics for specific mass, specific volume, deployed area, deployed solar array wing (SAW) keep in zone (KIZ), deployed strength and deployed frequency. Analytical and design results are presented that support definition of stowed KIZ and launch restraint interface definition. An offset boom is defined to meet the deployed SAW KIZ. The resulting parametric impact of the offset boom length on spacecraft moment of inertias and deployed SAW quasistatic and dynamic load cases are also presented. Load cases include ARM spacecraft thruster plume impingement, asteroid surface operations and Orion docking operations which drive the required SAW deployed strength and damping. The authors conclude that to support NASA's ARM power needs, an advanced SAW is required with mass performance better than 125 W/kg, stowed volume better than 40 kW/cu m, a deployed area of 200 sq m (100 sq m for each of two SAWs), a deployed SAW offset distance of nominally 3-4 m, a deployed SAW quasistatic strength of nominally 0.1 g in any direction, a deployed loading displacement under 2 m, a deployed fundamental frequency above 0.1 Hz and deployed damping of at least 1%. These parameters must be met on top of challenging mission environments and ground testing requirements unique to the ARM project.

solar arrays↗
NASA NTRS2006

Impact of Solar Array Position on ISS Vehicle Charging

The International Space Station (ISS), because of its large structure and high voltage solar arrays, has a complex plasma interaction with the ionosphere in low Earth orbit (LEO). This interaction of the ISS US Segment photovoltaic (PV) power system with the LEO ionospheric plasma produces floating potentials on conducting elements of the ISS structure relative to the local plasma environment. To control the ISS floating potentials, two Plasma Contactor Units (PCUs) are installed on the Z1 truss. Each PCU discharges accumulated electrons from the Space Station structure, thus reducing the potential difference between the ISS structure and the surrounding charged plasma environment. Operations of the PCUs were intended to keep the ISS floating potential to 40 Volts (Reference 1). Exposed dielectric surfaces overlying conducting structure on the Space Station will collect an opposite charge from the ionosphere as the ISS charges. In theory, when an Extravehicular Activity (EVA) crewmember is tethered to structure via the crew safety tether or when metallic surfaces of the Extravehicular Mobility Unit (EMU) come in contact with conducting metallic surfaces of the ISS, the EMU conducting components, including the perspiration-soaked crewmember inside, can become charged to the Space Station floating potential. The concern is the potential dielectric breakdown of anodized aluminum surfaces on the EMU producing an arc from the EMU to the ambient plasma, or nearby ISS structure. If the EMU arcs, an electrical current of an unknown magnitude and duration may conduct through the EVA crewmember, producing an unacceptable condition. This electrical current may be sufficient to startle or fatally shock the EVA crewmember (Reference 2). Hence, as currently defined by the EVA community, the ISS floating potential for all nominal and contingency EVA worksites and translation paths must have a magnitude less than 40 volts relative to the local ionosphere at all times during EVA. Arcing from the EMU is classified as a catastrophic hazard, which requires two-failure tolerant controls, i.e., three hazard controls. Each PCU is capable of maintaining the ISS floating potential below the requirement during EVA. The two PCUs provide a single failure tolerant control of ISS floating potential. In the event of the failure of one or two PCUs, a combination of solar array shunting and turning the solar arrays into their own wakes will be used to supply control of the plasma hazard (Reference 3). The purpose of this paper is to present on-orbit information that shows that ISS solar array placement with respect to the ISS velocity vector can control solar array plasma charging, and hence, provide an operational control for the plasma hazard. Also, this paper will present on-orbit information that shows that shunting of the ISS solar arrays can control solar array plasma charging, and hence, provide an additional operational control for the plasma hazard.

Alred, John↗
NASA NTRS2017

On-Orbit Structural Dynamics Performance of the Roll-Out Solar Array

The Roll-Out Solar Array (ROSA) flight experiment was launched to the International Space Station (ISS) on June 3rd, 2017. ROSA is an innovative, lightweight solar array with a flexible substrate that makes use of the stored strain energy in its composite structural members to provide deployment without the use of motors. This paper will discuss the results of various structural dynamics experiments conducted on the ISS during the weeks following launch. Data gathered from instrumentation on the solar array wing during the experiments are compared with pre-flight predictions from two different finite element modeling efforts. Two distinct methods were used to reconstruct the modal characteristics of ROSA from the data collected on orbit. Of particular interest in this effort are the first few system modes and mode shapes of the array, the amount of structural damping present, and degree of structural thermal interaction seen during eclipse exit. Discrepancies between the behavior predicted by the models and that observed on orbit are identified and discussed. The goal in this effort was to better understand the performance of ROSA and to improve modeling efforts for future designs of similar solar arrays.

Chamberlain, Matthew K.↗
NASA NTRS1981

Summary of LSST systems analysis and integration task for SPS flight test articles

The structural and equipment requirements for two solar power satellite (SPS) test articles are defined. The first SPS concept uses a hexagonal frame structure to stabilize the array of primary tension cables configured to support a Mills Cross antenna containing 17,925 subarrays composed of dipole radiating elements and solid state power amplifier modules. The second test article consists of a microwave antenna and its power source, a 20 by 200 m array of solar cell blankets, both of which are supported by the solar blanket array support structure. The test article structure, a ladder, is comprised of two longitudinal beams (215 m long) spaced 10 m apart and interconnected by six lateral beams. The system control module structure and bridge fitting provide bending and torsional stiffness, and supplement the in plane Vierendeel structure behavior. Mission descriptions, construction, and structure interfaces are addressed.

Greenberg, H. S.↗
NASA NTRS1992

Synergistic effects of ultraviolet radiation, thermal cycling, and atomic oxygen on altered and coated Kapton surfaces

The photovoltaic (PV) power system for Space Station Freedom (SSF) uses solar array blankets which provide structural support for the solar cells and house the electrical interconnections. In the low Earth orbital (LEO) environment where SSF will be located, surfaces will be exposed to potentially damaging environmental conditions including solar ultraviolet (UV) radiation, thermal cycling, and atomic oxygen. It is necessary to use ground based tests to determine how these environmental conditions would affect the mass loss and optical properties of candidate SSF blanket materials. Silicone containing, silicone coated, and SiO(x) coated polyimide film materials were exposed to simulated LEO environmental conditions to determine there durability and whether the environmental conditions of UV, thermal cycling and oxygen atoms act synergistically on these materials. A candidate PV blanket material called AOR Kapton, a polysiloxane polyimide cast from a solution mixture, shows an improvement in durability to oxygen atoms erosion after exposure to UV radiation or thermal cycling combined with UV radiation. This may indicate that the environmental conditions react synergistically with this material, and the damage predicted by exposure to atomic oxygen alone is more severe than that which would occur in LEO where atomic oxygen, thermal cycling and UV radiation are present together.

Dever, Joyce A.↗
NASA NTRS1992

Synergistic effects of ultraviolet radiation, thermal cycling and atomic oxygen on altered and coated Kapton surfaces

The photovoltaic (PV) power system for Space Station Freedom (SSF) uses solar array blankets which provide structural support for the solar cells and house the electrical interconnections. In the low earth orbital (LEO) environment where SSF will be located, surfaces will be exposed to potentially damaging environmental conditions including solar ultraviolet (UV) radiation, thermal cycling, and atomic oxygen. It is necessary to use ground based tests to determine how these environmental conditions would affect the mass loss and optical properties of candidate SSF blanket materials. Silicone containing, silicone coated, and SiO(x) coated polyimide film materials were exposed to simulated LEO environmental conditions to determine their durability and whether the environmental conditions of UV, thermal cycling and oxygen atoms act synergistically on these materials. A candidate PV blanket material called AOR Kapton, a polysiloxane polyimide cast from a solution mixture, shows an improvement in durability to oxygen atoms erosion after exposure to UV radiation or thermal cycling combined with UV radiation. This may indicate that the environmental conditions react synergistically with this material, and the damage predicted by exposure to atomic oxygen alone is more severe than that which would occur in LEO where atomic oxygen, thermal cycling and UV radiation are present together.

Dever, Joyce A.↗
NASA NTRS1980

Satellite power systems (SPS) concept definition study. Volume 2, part 1: System engineering

Top level trade studies are presented, including comparison of solid state and klystron concepts, higher concentration on the solar cells, composite and aluminum structure, and several variations to the reference concept. Detailed trade studies are presented in each of the subsystem areas (solar array, power distribution, structures, thermal control, attitude control and stationkeeping, microwave transmission, and ground receiving station). A description of the selected point design is also presented.

Hanley, G. M.↗
NASA NTRS2018

The SPACE Computer Code for Analyzing the International Space Station Electrical Power System: Past, Present, and Future

The System Power Analysis for Capability Evaluation (SPACE) computer code was initially developed by NASA in 1988 to assess the Space Station Freedom electric power system and later adapted to support contractor electrical power system capability analyses for the International Space Station (ISS). Over time, the code has supported many efforts such as ISS redesign activities in the early 1990s, assessment of time-phased loads against power system operating limits for future ISS assembly flights (including Certification of Flight Readiness reviews by the ISS program office), and determining the optimum solar array gimbal positions while respecting keep-out zones which minimize both solar array contamination and structural loads. The code has been validated by comparisons with ISS on-orbit data in multiple validation episodes. Recent updates to the code include the incorporation of a Lithium-Ion battery model in addition to the Nickel Hydrogen battery model and modifications to the solar array degradation model to better match on-orbit test results. SPACE has also been extended beyond the ISS to include modeling of the Orion Multi-Purpose Crew Vehicle electrical power system (SPACE-MPCV) and Mars Surface Electrical Power Systems (MSEPS). Portions of SPACE were integrated with a trajectory code to form a Solar Electric Propulsion Simulation (SEPSim), which can be used for analyzing solar electric propulsion missions. In addition, SPACE methods and subroutines have been adapted to a multitude of other projects. This paper summarizes the initial code development and subsequent code utilization in the context of the overall ISS program development and on-orbit operations. Recent updates and results from the code are discussed, including preliminary analyses for the Orion power system.

Electrical Power System↗
NASA NTRS2002

The Stretched Lens Array (SLA): An Ultra-Light Photovoltaic Concentrator

A high-performance, ultralight, photovoltaic concentrator array is being developed for space power. The stretched lens array (SLA) uses stretched-membrane, silicone Fresnel lenses to concentrate sunlight onto triple-junction photovoltaic cells. The cells are mounted to a composite radiator structure. The entire solar array wing, including lenses, photovoltaic cell flex circuits, composite panels, hinges, yoke, wiring harness, and deployment mechanisms, has a mass density of 1.6 kg/sq.m. NASA Glenn has measured 27.4% net SLA panel efficiency, or 375 W/sq.m. power density, at room temperature. At GEO operating cell temperature (80 C), this power density will be 300 W/sq.m., resulting in more than 180 W/kg specific power at the full wing level. SLA is a direct ultralight descendent of the successful SCARLET array on NASA's Deep Space 1 spacecraft. This paper describes the evolution from SCARLET to SLA, summarizes the SLA's key features, and provides performance and mass data for this new concentrator array.

ONeill, Mark J.↗
NASA NTRS2002

Development of the Ultra-Light Stretched Lens Array

At the last IEEE (Institute of Electrical and Electronics Engineers) PVSC (Photovoltaic Specialists Conference), the new stretched lens array (SLA) concept was introduced. Since that conference, the SLA team has made significant advances in the SLA technology, including component level improvements, array level optimization, space environment exposure testing, and prototype hardware fabrication and evaluation. This paper will describe the evolved version of the SLA, highlighting the improvements in the lens, solar cell, rigid panel structure, and complete solar array wing. The near term SLA will provide outstanding wing level performance: greater than 180 W/kg specific power, greater than 300 W/sq m power density, greater than 300 V operational voltage, and excellent durability in the space environment.

O'Neill, M. J.↗
NASA NTRS2002

The Stretched Lens Array (SLA): A Low-Risk, Cost-Effective Array Offering Wing-Level Performance of 180 W/KG and 300 W/M2 at 300 VDC

At IECEC 2001, our team presented a paper on the new stretched lens array (SLA), including its evolution from the successful SCARLET array on the NASA/JPL Deep Space 1 spacecraft. Since that conference, the SLA team has made significant advances in the SLA technology, including component-level improvements, array-level optimization, space environment exposure testing, and prototype hardware fabrication and evaluation. This paper describes the evolved version of the SLA, highlighting recent improvements in the lens, solar cell, photovoltaic receiver, rigid panel structure, and complete solar array wing.

ONeill, Mark↗
NASA NTRS2009

Acoustically Induced Vibration of Structures: Reverberant Vs. Direct Acoustic Testing

Large reverberant chambers have been used for several decades in the aerospace industry to test larger structures such as solar arrays and reflectors to qualify and to detect faults in the design and fabrication of spacecraft and satellites. In the past decade some companies have begun using direct near field acoustic testing, employing speakers, for qualifying larger structures. A limited test data set obtained from recent acoustic tests of the same hardware exposed to both direct and reverberant acoustic field testing has indicated some differences in the resulting structural responses. In reverberant acoustic testing, higher vibration responses were observed at lower frequencies when compared with the direct acoustic testing. In the case of direct near field acoustic testing higher vibration responses appeared to occur at higher frequencies as well. In reverberant chamber testing and direct acoustic testing, standing acoustic modes of the reverberant chamber or the speakers and spacecraft parallel surfaces can strongly couple with the fundamental structural modes of the test hardware. In this paper data from recent acoustic testing of flight hardware, that yielded evidence of acoustic standing wave coupling with structural responses, are discussed in some detail. Convincing evidence of the acoustic standing wave/structural coupling phenomenon will be discussed, citing observations from acoustic testing of a simple aluminum plate. The implications of such acoustic coupling to testing of sensitive flight hardware will be discussed. The results discussed in this paper reveal issues with over or under testing of flight hardware that could pose unanticipated structural and flight qualification issues. Therefore, it is of paramount importance to understand the structural modal coupling with standing acoustic waves that has been observed in both methods of acoustic testing. This study will assist the community to choose an appropriate testing method and test setup in the planning stages.

Reverberant acoustic field↗