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1 American Institute of Aeronautics and Astronautics Illumination Testing Was Done at NASA’S John H AIAA-2000-2881 PROTOTYPE SOLAR PANEL DEVELOPMENT AND TESTING FOR A MERCURY ORBITER SPACECRAFT Carl J. Ercol, Jason E. Jenkins, George Dakermanji, Andrew G. Santo The Johns Hopkins University Applied Physics Laboratory Laurel, MD 20723-6099 Lee S. Mason NASA John H. Glenn Research Center at Lewis Field 21000 Brookpark Road, MSAAC-2 Cleveland, OH 44135 ABSTRACT Optical Solar Reflectors (OSRs) and the same type of GaAs/Ge cells. Each side of each solar panel is designed to maximize power generation and minimize operating A Mercury orbiting spacecraft imposes many design temperature for a given solar distance range. From launch challenges in the area of spacecraft thermal control and until the spacecraft reaches about 0.60 Astronomical electrical power generation. The Discovery Mission Units (AU), where the solar constant is about 2.8 greater MESSENGER (MErcury Surface, Space, ENvironment, than at Earth, the fully packed side of each array is GEochemistry, and Ranging), being designed and built responsible for power generation. Once inside of 0.60 by The Johns Hopkins University Applied Physics AU, the array is flipped to the 30% cell side which takes Laboratory (APL), will orbit and survey the planet advantage of the higher solar constant while maintaining Mercury for one year. In order to reduce cost and schedule the solar panel operating temperature below 150°C. risk while increasing the probability for mission success, The solar panel structure uses sandwich the MESSENGER solar arrays will be constructed from construction comprised of high thermal-conductivity conventional “off the shelf” materials and technologies. graphite-epoxy (Gr/Ep) face-skins and an aluminum- honeycomb core. The primary thermal environment that INTRODUCTION drives the MESSENGER prototype solar panel design and the dual-sided configuration is the high solar intensity This paper describes the high temperature and high condition experienced when at planet perihelion, where intensity illumination testing which were used to the solar constant is eleven times that at Earth. The thermally evaluate a series of prototype engineering solar mirrored side of the array safeguards against solar panel panel concepts. Since all of the materials, construction temperatures exceeding 250°C in the event of a direct techniques and technologies chosen for the solar panel Sun pointing anomaly when at Mercury perihelion. And, construction are typically used for fairly benign thermal the dual sided design minimizes the solar panel overall environments, qualification or proof of concept testing size and mass by using the fully packed face at solar was necessary to assess the risks associated with such a distances associated with the beginning of the mission thermally demanding mission. The solar array concept when temperatures are very benign and the solar constant for the MESSENGER Mission consists of two double is low. sided rotatable wings, allowing for tailored temperature A large portion of the proof of concept thermal control during power generation as solar distance vacuum testing was accomplished using a custom decreases. One side of each array is fully packed with designed high temperature infrared oven to test solar 5.5 mil single junction gallium arsenide (GaAs/Ge) cells. panel specimens between +300°C and –105°C. The oven The opposite side is packed with a 70%/30% mixture of has allowed for accurate and repeatable component testing while proving to be very reliable and cost effective. The more expensive and complicated high intensity solar illumination tests were done only after thorough infrared Copyright © 2000 The American Institute of Aeronau- temperature cycle testing and high temperature soaks tics and Astronautics Inc. All rights reserved. verified solar panel materials and construction. The high- 1 American Institute of Aeronautics and Astronautics illumination testing was done at NASA’s John H. Glenn mass must be used with great discretion since the main Research Center at Lewis Field in the Tank 6 high purpose of the mission is to get maximum science return. intensity vacuum chamber. These tests were used to verify Figure 1 illustrates the MESSENGER spacecraft. As the prototype solar panel thermal design and to shown, the dual-sided solar panel wings extend beyond demonstrate ability to predict the expected test panel the protective umbra created by the thermal shade, temperature at a high intensity solar simulated making the solar arrays the only critical component environment. The paper describes the details and results exposed to direct high intensity solar illumination. of the prototype tests conducted along with plans for the Designing the spacecraft for minimum mass will require flight solar panel development and test. the attention of all spacecraft sub-systems, and the seemingly vulnerable solar array is no exception. A mass BACKGROUND saving benefit from the dual-sided approach is that the overall solar panel area is small because each face is Mercury has never been explored by a remote optimized for power at the worst case solar distance and orbiting spacecraft. The only man-made space probe to temperature. Each face of the dual sided solar array is visit Mercury was Mariner 10. Built and launched in the designed to produce power at a cell operating temperature United States, Mariner 10, a 3-axis stabilized solar of 150°C or lower. As illustrated by Figure 2, the array is powered spacecraft, has provided the only images and flipped from the fully packed side to the OSR side and scientific exploration of Mercury. Using three flybys, back as the solar distance varies between approximately Mariner 10 was able to map only about 45% of the planet 0.45 and 0.60 AU. Figure 3 illustrates the variation in surface during a one-year period between 1974–1975. respective solar array face rotation angle as a function of The dark side flybys were all at planet aphelion and never solar distance as the array temperature is held at or below near the sub-solar point. Mariner 10 was designed and 150°C. The rotation angle is zero when the Sun line is tested to withstand a solar-only 5 Sun (one Sun is equal perpendicular to the active face of the solar array. to the solar flux at 1 AU or 1365 W/m2) environment, ignoring the intense omni-directional heat radiated from Why Use a Dual-Sided Solar Array Concept? Mercury’s surface on the Sun-lit side. The MESSENGER mission first baselined a single Due to severe mass restrictions and extremely harsh sided fully packed solar array using single junction GaAs/ thermal environments, a Mercury orbiting spacecraft Ge cells bonded to graphite composite substrates. As poses many engineering and operational challenges. illustrated by Figure 4, the fully packed solar array has MESSENGER is a 3-axis stabilized solar powered to be rotated in excess of 75° to maintain the steady state spacecraft using a high-performance all chemical solar array temperatures below the desired operating point propulsion system fully integrated into an all graphite- of 150°C while at Mercury perihelion (11-Sun epoxy structure. The power system will utilize two low illumination condition). A major deficiency with this mass dual-sided solar array wings that can be rotated and design is that a direct Sun pointing anomaly at the flipped as necessary to control solar panel temperatures perihelion solar distance could easily cause the array to as the spacecraft approaches Mercury perihelion. The approach 400°C. Solar cell and Gr/Ep adhesives are only mission design uses a ballistic trajectory with multiple rated to maximum temperatures between 200 and 260°C. Venus and Mercury gravity assists. The MESSENGER spacecraft will eventually orbit Mercury for one Earth year (or four Mercurian years) and return a wealth of scientific data and complete planet coverage, something not accomplished by Mariner 10. The MESSENGER mission was recently selected by NASA to be the eighth program in the highly successful series of the Discovery missions. Mission cost and launch vehicle choices are very constrained under NASA Discovery guidelines. The largest acceptable launch vehicle for a NASA Discovery mission is a Boeing Delta II 7925H-9.5 (Maximum Launch Mass=1066 kg). Driven by the 2700 meter per second mission ∆-velocity (∆V) requirements, over one half of the launch mass is allocated to propellant. It quickly becomes apparent that due to the high ∆V nature of this mission, the spacecraft Figure 1. MESSENGER spacecraft with body mounted mass allocated to useful payload is limited. Spacecraft multi-layer insulation (MLI) removed. 2 American Institute of Aeronautics and Astronautics 1.2 1 0.8 Fully Packed Side 0.6 Solar Panel Flip Zone 0.4 Cell / OSR Side Spacecraft Solar Distance (AU) 0.2 Cruise Phase Orbit Phase 0 0 500 1000 1500 2000 2500 Mission Day Figure 2. The MESSENGER mission profile. Cruise phase is five years and orbit phase is one year. 90 80 Rotation angles greater than zero maintain 150oC ) 70 Θ 60 Fully Packed Side 50 40 Cell / OSR Side 30 Solar Panel Flip Zone 20 Solar Array Rotation Angle ( θ Solar Panel 10 0 0.3 0.35 0.4 0.45 0.5 0.55 0.6 0.65 0.7 Solar Distance (AU) Figure 3. The solar panels are rotated to maintain the maximum temperatures at or below 150°C. The dual sided solar arrays have a wide flip zone to reduce operational constraints and minimize risks. 3 American Institute of Aeronautics and Astronautics 400 Fully Packed Side C) 350 o C) ° 300 250 30% Cell / 70% OSR Side 200 150 θ Solar Panel 100 Operation Range 50 Steady State Solar Panel Temperature ( Temperature State Solar Panel Steady Steady State Solar Panel Temperarure ( 0 0 1020304050607080 Solar Array Rotation Angle (Θ) When at Perihelion Figure 4. The OSR array side will maintain the steady state solar panel temperature below 260°C if Sun pointed when at perihelion.
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