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The cost of transportation to the lunar surface places a premium on developing ultralightweight power system technology to support the eventual establishment of a lunar base. The photovoltaic technology issues to be addressed by the Surface Power program element of NASA's Project Pathfinder are described.
Direct current (dc) motors are used in terrestrial photovoltaic (PV) systems such as in water-pumping systems for irrigation and water supply. Direct current motors may also be used for space applications. Simple and low weight systems including dc motors may be of special interest in space where the motors are directly coupled to the solar cell array (with no storage). The system will operate only during times when sufficient insolation is available. An important performance characteristic of electric motors is the starting to rated torque ratio. Different types of dc motors have different starting torque ratios. These ratios are dictated by the size of solar cell array, and the developed motor torque may not be sufficient to overcome the load starting torque. By including a maximum power point tracker (MPPT) in the PV system, the starting to rated torque ratio will increase, the amount of which depends on the motor type. The starting torque ratio is calculated for the permanent magnet, series and shunt excited dc motors when powered by solar cell arrays for two cases: with and without MPPT's. Defining a motor torque magnification by the ratio of the motor torque with an MPPT to the motor torque without an MPPT, a magnification of 3 was obtained for the permanent magnet motor and a magnification of 7 for both the series and shunt motors. The effect of the variation of solar insolation on the motor starting torque was covered. All motor types are less sensitive to insolation variation in systems including MPPT's as compared to systems with MPPT's. The analysis of this paper will assist the PV system designed to determine whether or not to include an MPPT in the system for a specific motor type.
Phase 2 of the Advanced Photovoltaic Solar Array (APSA) program, started in mid-1987, is currently in progress to fabricate prototype wing hardware that will lead to wing integration and testing in 1989. The design configuration and key details are reviewed. A status of prototype hardware fabricated to date is provided. Results from key component-level tests are discussed. Revised estimates of array-level performance as a function of solar cell device technology for geosynchronous missions are given.
Work Package Four, which includes the NASA-Lewis and Rocketdyne, has selected an approach for the Space Station Freedom Photovoltaic (PV) Power Module flight certification that combines system level qualification and acceptance testing in the thermal vacuum environment: The protoflight vehicle approach. This approach maximizes ground test verification to assure system level performance and to minimize risk of on-orbit failures. The preliminary plans for system level thermal vacuum environmental testing of the protoflight PV Power Module in the NASA-Lewis Space Power Facility (SPF), are addressed. Details of the facility modifications to refurbish SPF, after 13 years of downtime, are briefly discussed. The results of an evaluation of the effectiveness of system level environmental testing in screening out incipient part and workmanship defects and unique failure modes are discussed. Preliminary test objectives, test hardware configurations, test support equipment, and operations are presented.
Electric power generation for Space Station Freedom will be provided by four photovoltaic (PV) power modules using silicon solar cells during Phase 1 operation. Each PV power module requires two solar arrays with 32,800 solar cells generating 18.75 kW of dc power for a total of 75 kW. A portion of this power will be stored in nickel-hydrogen batteries for use during eclipse, and the balance will be processed and converted to 20 kHz ac power for distribution to end users through the power management and distribution system. The design incorporates an optimized thermal control system, pointing and tracking provision with the application of gimbals, and the use of orbital replacement units (ORU's) to achieve modularization. Design status of the PV power module, as derived from major trade studies, is discussed at hardware levels ranging from component to system. Details of the design are presented where appropriate.
The National Aeronautics and Space Administration recently embarked on the Space Station Freedom program, which will utilize the Shuttle Orbiter for transportation to orbit. This task will be accomplished with a number of flights over several years. Each flight is unique in terms of the hardware that is manifested and the method by which it is integrated to form viable cargo elements. Work Package 4 is responsible for the electric power system for Space Station Freedom, and was delegated the authority to develop a photovoltaic (PV) power module cargo element. The PV power module consists of several unique assemblies. The first of these is the combined solar array/beta gimbal assembly. The remaining assemblies form the single combined integrated equipment assembly for each PV power module. These three combined assemblies are packaged into a launch cradle to form the PV power module cargo element, which is placed in the cargo bay of the Shuttle Orbiter for transportation to orbit. Various constraints determine the packaging options for the three PV power module combined assemblies. The size and shape of the combined assemblies in relation to the Shuttle Orbiter cargo bay dimensions and other manifested hardware are ultimately a factor in determining the acceptable packaging schemes for the PV power module cargo element. Several packaging options for the PV power module cargo element are presented. These options are discussed in terms of their impact on the overall flight hardware manifest as determined by the various constraints.
The present stature and current research directions of photovoltaic arrays as primary power systems for space are reviewed. There have recently been great advances in the technology of thin-film solar cells for terrestrial applications. In a thin-film solar cell the thickness of the active element is only a few microns; transfer of this technology to space arrays could result in ultralow-weight solar arrays with potentially large gains in specific power. Recent advances in thin-film solar cells are reviewed, including polycrystalline copper-indium selenide (CuInSe2) and related I-III-VI2 compounds, polycrystalline cadmium telluride and related II-VI compounds, and amorphous silicon:hydrogen and alloys. The best experimental efficiency on thin-film solar cells to date is 12 percent AMO for CuIn Se2. This efficiency is likely to be increased in the next few years. The radiation tolerance of thin-film materials is far greater than that of single-crystal materials. CuIn Se2 shows no degradation when exposed to 1 MeV electrons. Experimental evidence also suggests that most of all of the radiation damage on thin-films can be removed by a low temperature anneal. The possibility of thin-film multibandgap cascade solar cells is discussed, including the tradeoffs between monolithic and mechanically stacked cells. The best current efficiency for a cascade is 12.5 percent AMO for an amorphous silicon on CuInSe2 multibandgap combination. Higher efficiencies are expected in the future. For several missions, including solar-electric propulsion, a manned Mars mission, and lunar exploration and manufacturing, thin-film photovolatic arrays may be a mission-enabling technology.
The proposed Space Station Photovoltaic Deployable Boom was analyzed for operating temperatures. The boom glass/epoxy structure design needs protective shielding from environmental degradation. The protective shielding optical properties (solar absorptivity and emissivity) dictate the operating temperatures of the boom components. The Space Station Boom protective shielding must also withstand the effects of the extendible/retractable coiling action within the mast canister. A thermal analysis method was developed for the Space Station Deployable Boom to predict transient temperatures for a variety of surface properties. The modeling procedures used to evaluate temperatures within the boom structure incorporated the TRASYS, NEVADA, and SINDA thermal analysis programs. Use of these programs led to a comparison between TRASYS and NEVADA analysis methods. Comparing TRASYS and NEVADA results exposed differences in the environmental solar flux predictions.
One of the elements of the Space Station Freedom power system is the Photovoltaic (PV) module. These modules will be assembled on-orbit during the assembly phase of the program. These modules will be assembled either from the shuttle orbiter or from the Mobile Servicing Center (MSC). The different types of assembly operations that will be used to assemble PV Modules are described.
The current development status of ultralightweight flexible-blanket foldout solar arrays being designed and fabricated under the NASA Advanced Photovoltaic Solar Array (APSA) program is surveyed. The goal of APSA is the construction of a 25-kW array with specific power 300 W/kg (BOL) by the year 2000. Topics discussed here include array configurations, blanket deployment systems, prototype wing-hardware fabrication, component-level test results, solar-cell technologies, and array performance estimates. Diagrams, drawings, graphs, and tables of numerical data are provided.
The capability and the safety of manned spacecraft are largely dependent upon reliable electric power systems. Two similar space power systems able to survive the low earth orbit environment, are being considered for NASA's Manned Space Station (SS), scheduled to begin operation in the mid 1990's. The Space Station Electric Power System (EPS) is composed of Photovoltaic (PV) Power Modules, Solar Dynamic (SD) Power Modules, and the Power Management and Distribution (PMAD) System. One EPS configuration will deliver 37.5 kW of PV based, utility grade, ac power to SS users. A second 75 kWe PV based EPS option is also being considered for SS deployment. The two EPS options utilize common modules and differ only in the total number of PV Power Modules used. Each PV Power Module supplies 18.75 kWe of ac power and incorporates its own energy storage and thermal control. The general requirements and the current preliminary design configuration of the Space Station PV Power Modules are examined.
An asymmetric delta-doped GaAs structure is described which exhibits novel photovoltaic effects and low-intensity nonlinear optics. Of particular interest in this kind of structure is the ability to design the electrooptical and nonlinear optical properties and the material response time over a wide range by appropriate design of the doping profile.
The development of photovoltaic arrays beyond the next generation is discussed with attention given to the potentials of thin-film polycrystalline and amorphous cells. Of particular importance is the efficiency (the fraction of incident solar energy converted to electricity) and specific power (power to weight ratio). It is found that the radiation tolerance of thin-film materials is far greater than that of single crystal materials. CuInSe2 shows no degradation when exposed to 1-MeV electrons.
This paper provides details on the Advanced Photovoltaic Solar Array (APSA) wing design, fabrication, and testing. The impact of array size change on performance and mechanical characteristics is discussed. Projections for future performance enhancements that may be expected through the use of advanced solar cells presently under development are examined.
Additional features increase sensitivity and utility. Modifications proposed to improve device described in "Photovoltaic-Driven Multiple-Quantum-Well Modulator" (NPO-16914) and "Strain-Layer-Superlattice Light Modulator" (NPO-16915). Resembles prior devices of this general type but includes active region using quantum state filling and more optimum structure. Exploits quantum well equivalent of Moss-Burnstein shift.
The background and development status of an ultralightweight flexible-blanket flatpack, fold-out solar array is presented. It is scheduled for prototype demonstration in late 1989. The Advanced Photovoltaic Solar Array (APSA) design represents a critical intermediate milestone of the goal of 300 W/kg at beginning-of-life (BOL) with specific performance characteristics of 130 W/kg (BOL) and 100 W/kg at end-of-life (EOL) for a 10-year geosynchronous geostationary earth orbit 10-kW (BOL) space power system. The APSA wing design is scalable over a power range of 2 to 15 kW and is suitable for a full range of missions including Low Earth Orbit (LEO), orbital transfer from LEO to geostationary earth orbit and interplanetary flight.
Space Station Freedom is described with special attention given to its electric power system. The photovoltaic arrays, the battery energy storage system, and the power management, and distribution system are also discussed. The current design of Freedom's power system and the system requirements, trade studies, and competing factors which lead to system selections are referenced. This will be the largest power system ever flown in space. This system represents the culmination of many developments that have improved system performance, reduced cost, and improved reliability. Key developments and their evolution into the current space station solar array design are briefly described. The features of the solar cell and the array including the development, design, test, and flight hardware production status are given.
The electrochemical and galvanic corrosion properties of thin-film photovoltaic (TF-PV) modules and module subcomponents are determined and interpreted in the light of established corrosion science. Results of a detailed study of thin-film aluminum metallization corrosion are presented. Bar-graph corrosion, observed in fielded modules, has been induced experimentally and found to be electrochemical in nature. Corrosion rates and passivation techniques for TF-PV modules are discussed.