Boeing High Power Thin Film Solar Array

Abstract

The Boeing High Power Thin-Film Solar Array Architecture (US Patent 6983914) is a revolutionary technology for providing extremely high power to spacecraft using thin film solar cell technology. The architecture generates over 130kW Beginning of Life (BOL) power with 9% efficient amorphous silicon solar cells and still meets the weight and volume constraints for launch on a single conventional launch vehicle. Other thin film technologies including CIGS and thinned out 30% multi-junction cells can be incorporated for higher power. This technology is applicable to multiple missions including: solar powered satellites in any orbit, deep space transit vehicles utilizing electric propulsion, and power for orbit raising. The architecture is highly versatile, inherently modular, and scalable. This report presents several mechanical configurations with up to 10 modules deployed in an array of 2 solar wings attached to either side of a spacecraft via a small yoke structure. The wings are deployed in multiple stages. First the yoke and modules extend out from the spacecraft in a concertina fashion and lock up to form a long rigid pipe-like structure that makes up the stiff structural spine of the deployed wing. Next the individual modules unroll one at a time to expose the solar panels. Each deployed module has the main stiff pipe-like structure in the center with a 50-foot light and flexible solar panel extending from each side. The intricate deployment is covered in detail. The deployed panels are held taut in a predictable and precise position by means of a very unique, lightweight system of Bow Beams, Tether Cords, Tether Poles, and a flexible attachment to an End Beam. The minimal use of electrical harnessing is made possible by using the structure for the power return current. Trade studies for optimizing the power, mass, stiffness, manufacturability and costs are presented for the major structural and geometrical features of the solar wing. The system level performance values for power, mass, specific power (power/mass), stiffness, and cost efficiency are displayed for 4 different configurations. Larger arrays may be possible by adding more modules. 4th International Energy Conversion Engineering Conference and Exhibit (IECEC) 26 29 June 2006, San Diego, California AIAA 2006-4013