SBIR-STTR Award

Conventional deployable arrays of rigid solar panels use cables or added external structures to provide synchronized deployment, adding mass, volume and limiting applicability, and are custom engineered for each application with unique assembly and integration processing and fixtures. This SBIR develops a novel Integrated Deployable Array which uses a multi-functional modular rigid solar panel that provides both panel structural support and synchronized deployment. The integrated system engineering approach uses multi-functionality to reduce total mass, improve stowed volume, and provide flexibility in application to variety of panel sizes and number of panels. The approach adopts the advantages of modularity and standardization of the MOSAIC modular solar panel developed in a prior SBIR, with easy life-cycle processing, standardizing interfaces to the array assembly fixture, the Ground Support Equipment, the shipping container, the Hold-Down and Release mechanism, and the spacecraft integration fixtures. The Phase I effort completes the conceptual design of an Integrated Deployable Array including deployment mechanism and drives, performs preliminary static, dynamic and kinematic analysis, and optimizes the design for mass and volume. A proof of concept multi-panel deployment test article is assembled to demonstrate ease of assembly, modularity, and synchronized deployment under ambient conditions, in multiple configurations.

Benefit:
The development of a standardized, modular approach to rigid deployable solar array will significantly reduce non-recurring engineering, and its associated schedule and cost, which represents a significant fraction of the total cost for deployable arrays. Ease of assembly and ability to integrate into arrays of different sizes and number of panels provides the greatest applicability of the design. With standardization also comes improved reliability from improved qualification traceability and manufacturing process control. Commercial application is particularly suitable to small spacecraft with prime power requirements of 500-5,000 Watts, where the non-recurring engineering costs and impacts of customized unique designs are a high fraction of total solar array costs.

Keywords:
Solar Array, Deployable, Modularity, Spacecraft Power, Synchronization

Conventional rigid-panel solar arrays are deployed with complex mechanisms or dynamically-tuned and damped hinges, with cables or external linkages for synchronization. Altering the number or size of panels incurs significant new engineering, tooling, manufacturing and integration. This SBIR develops the Modular Advanced Synchronization Technology (MAST) deployable array that uses multi-functional panels with internal linkages that synchronize hinges having integral distributed motive force for simple, passive deployment and lock-up. The approach is fully modular and easily adaptable to different sizes of solar panels and because of the distributed deployment force, different numbers of panels per wing, reducing NRE and schedule. The development has emphasized maximum use of modified COTS parts for low cost, and high performance composites for low mass. In Phase I, we designed, analyzed and built a 3-panel demonstration which verified the hinge and synchronization approach. The Phase II builds upon these results, updating the panel-to-panel hinge design, developing the approach for a root panel hinge, hold-down and release interfaces, array deployable harness, and GSE. We fabricate a five panel array with representative structural properties, test the stowed array in launch environment, and perform hot and cold vacuum deployments to increase to TRL 5, showing readiness for flight qualification.

Benefit:
The standardization and reduced complexity of the MAST deployable array approach improves cost and reliability, key issues in all space solar array deployment, by applying a known qualified technology to a variety of array sizes and configurations. Because of its broad applicability, the approach could meet the requirements for higher performance and more cost-effective solar arrays in a variety of missions, from small spacecraft to very large ones. Reliable high power arrays at low cost could enable new spacecraft applications, including commercial space radar and earth observation platforms. The basic technology can also find commercial applications in other space deployable structures such as larger deployable antennas for commercial communication satellites, or even deployable space habitats for commercial space tourism.

Keywords:
Deployable solar arrays, spacecraft power systems, deployable structures, mechanisms