Low-profile solar array packaging and deployment for satellite

Abstract

A solar array assembly is provided. The solar array assembly includes multiple solar panels and a hinge mechanism. The hinge mechanism can couple the multiple solar panels to a side of a body of a satellite. The hinge mechanism is operable to transition the multiple solar panels between an extended configuration and a retracted configuration. In the extended configuration, the multiple solar panels are expanded from the side of the satellite along a longitudinal axis. In the retracted configuration, the multiple solar panels are folded against a bottom of the body.

Description

LOW-PROFILE SOLAR ARRAY PACKAGING AND DEPLOYMENT FOR SATELLITECROSS-REFERENCE TO RELATED APPLICATION

[0001] This application claims the benefit of U.S. Provisional Patent Application No. 63 / 527,959, filed in the U.S. Patent and Trademark Office on July 20, 2023, which is incorporated herein by reference in its entirety for all purposes.FIELD

[0002] The present disclosure relates generally to packaging and deploying solar arrays on satellites. Specifically, the configuration for packaging and deploying the solar arrays is low- profile and can be used with high-power satellites.BACKGROUND

[0003] Conventional solar arrays are stowed along the side panels of a spacecraft in a “z- fold” configuration. The conventional “z-fold” panels restrict the width of the panels, which causes a limitation on the overall surface area. Additionally, conventional “z-fold” panels limit the ability to stack satellites, which limits the number of satellites that can be manifested within a launch vehicle. As such, it is desired to have a configuration that can both accommodate panels with an increased surface area and provide a better ability to stack satellites in multi-manifest configurations.BRIEF DESCRIPTION OF THE DRAWINGS

[0004] Implementations of the present technology will now be described, by way of example only, with reference to the attached figures, wherein:

[0005] FIGS. 1A-1C illustrate solar arrays coupled to a satellite in a traditional z-fold configuration in a stowed configuration, deploying configuration, and deployed configuration, respectively;

[0006] FIG. 2 illustrates solar arrays coupled to a satellite in a stowed configuration, according to the present disclosure;

[0007] FIG. 3 illustrates solar arrays coupled to a satellite in a partially deployed configuration;

[0008] FIG. 4 illustrates solar arrays coupled to a satellite in a partially deployed configuration; and

[0009] FIG. 5 illustrates solar arrays coupled to a satellite in a deployed configuration.SUMMARY

[0010] The solar array assembly disclosed herein can provide multiple advantages over conventional configurations. As disclosed herein, the solar panels of each respective solar array assembly can be folded against the bottom of the body of a satellite in a retracted configuration and extended outward from the side of the body, along a longitudinal axis, in an extended configuration. Due to the internal dimensions (e.g., volume) of the launch vehicle fairing, stowing the solar panels underneath the body allows the solar panels to have an increased width (and correspondingly an increased surface area) over panels in conventional configurations. The increased surface area of the solar panels provides the solar array assemblies with greater power harvesting capability than those in conventional configurations. Moreover, stowing the solar panels underneath the body (e.g., opposite the payload in relation to the body) allows for larger primary structures (e.g., the primary structure can be up to the full diameter of the launch vehicle fairing), which increases the surface area over structures in conventional configurations. The larger surface area of the primary structure provides additional payload mounting and / or thermal dissipation over conventional configurations.

[0011] Aspects of the present disclosure include a solar array assembly that includes multiple solar panels and a hinge mechanism that can couple the solar panels to a side of a body of a satellite. The hinge mechanism can transition the solar panels between an extended configuration and a retracted configuration. In the extended configuration, the solar panels expand from the side of the satellite along a longitudinal axis. In the retracted configuration, the solar panels are folded against a bottom of the body.

[0012] In various possible examples, the hinge mechanism provides a first deployment motion and / or a second deployment motion. The first deployment motion allows the solar panels to pivot from the bottom of the body to the first side of the body. The second deployment motion allows the solar panels to unfurl to the extended configuration.

[0013] Aspects of the present disclosure include a satellite that includes a body. The body has a top, a bottom opposite the top, and a first side and a second side connecting opposing ends of the top and the bottom. In some examples, the body is operable to receive a payload on the top. A solar array assembly, which includes multiple solar panels, is coupled to the first side of the body. The solar panels are expanded from the first side of the body, along a longitudinal axis, when in an extended configuration. The solar panels are folded against the bottom of the body when in a retracted configuration.

[0014] In various possible examples, the solar array assembly is coupled to the first side by a first hinge mechanism. The first hinge mechanism provides a first deployment motion and / or a second deployment motion. The first deployment motion allows the solar panels to pivot from the bottom of the body to the first side of the body. The second deployment motion allows the solar panels to unfurl to the extended configuration. In various possible examples, the solar array assembly has a natural frequency greater than about 0.15 hertz when in the extended configuration.

[0015] In various possible examples, a second solar array assembly, which includes multiple solar panels, is coupled to the second side of the body. The solar panels are expanded from the second side of the body (e.g., opposite the first side of the body), along a longitudinal axis, when in an extended configuration. The solar panels are folded against the bottom of the body when in a retracted configuration.

[0016] In various possible examples, the second solar array assembly is coupled to the second side by a second hinge mechanism. The second hinge mechanism provides a first deployment motion and / or a second deployment motion. During the first deployment motion, the solar panels pivot from the bottom of the body to the first side of the body. During the second deployment motion, the solar panels unfurl to the extended configuration. In various possible examples, the second solar array assembly has a natural frequency greater than about 0.15 hertz when in the extended configuration.DETAILED DESCRIPTION

[0017] Various embodiments of the disclosure are discussed in detail below. While specific implementations are discussed, it should be understood that this is done for illustration purposes only. A person skilled in the relevant art will recognize that other components and configurations may be used without parting from the spirit and scope of the disclosure.

[0018] Additional features and advantages of the disclosure will be set forth in the description which follows, and in part will be obvious from the description, or can be learned by practice of the principles disclosed herein. The features and advantages of the disclosure can be realized and obtained by means of the instruments and combinations particularly pointed out in the appended claims. These and other features of the disclosure will become more fully apparent from the following description and appended claims, or can be learned by the practice of the principles set forth herein.

[0019] It will be appreciated that for simplicity and clarity of illustration, where appropriate, reference numerals have been repeated among the different figures to indicate corresponding or analogous elements. In addition, numerous specific details are set forth in order to provide a thorough understanding of the embodiments described herein. However, it will be understood by those of ordinary skill in the art that the embodiments described herein can be practiced without these specific details. In other instances, methods, procedures, and components have not been described in detail so as not to obscure the related relevant feature being described. The drawings are not necessarily to scale and the proportions of certain parts may be exaggerated to better illustrate details and features. The description is not to be considered as limiting the scope of the embodiments described herein.

[0020] Provided herein is a design for a satellite solar array packaging and deployment configuration that provides the ability to stow large solar array panels in a low stowage volume. In this design the dual solar array wings are folded underneath the satellite, which uses a novel structural configuration to provide a mechanical interface between the satellite and the launch vehicle. The dual wings are deployed via a hinged “gull-wing” mechanism that enables the panels to unfold along either side of the spacecraft. This configuration allows for maximizing the array width which allows for maximization of the array surface area and power harvesting capability while meeting the required stiffness requirements to ensure the natural frequency of the array is above 0.15 Hz by allowing increased width of the array panels within the available launch vehicle fairing volume. In addition, by packaging the solar arrays underneath the spacecraft, the satellite primary structure is able to extend and utilize up to the full available launch vehicle diameter which provides more surface area for payload mounting and thermal dissipation. Finally, this solar array packaging configuration can be used to either mount the satellite in a single-manifest configurationor stack the satellites in a multi-manifest configuration without changes to the primary structure design or deployment mechanism design.

[0021] Conventional solar arrays for high power satellites are stowed along the side panels of the spacecraft in a “z-fold” configuration. While this configuration provides a relatively simple deployment mechanism it suffers from a variety of deficiencies. For example, when stowed, the solar arrays must fit within the launch vehicle fairing diameter which limits the width of the panels. This width limitation in turn drives an overall surface area limitation due to the need to meet a minimum natural frequency requirement in the deployed configuration which is primarily driven by the aspect ratio of the deployed arrays. Also, the stowed arrays further limit the usable diameter for the primary structure, often requiring the satellite structure to use a reduced diameter which limits the size of the top and bottom panels for thermal dissipation and payload mounting area. Additionally, in the stowed configuration, the traditional z-folded panels limit the ability to stack the satellites in multi-manifest configurations within a launch vehicle due to interference between the upper and lower spacecraft. This limits the quantity of satellites that can be manifested within a launch vehicle. In the conventional z-fold configuration, the bottom or sides of the spacecraft are typically used to provide a mechanical interface to the launch vehicle.

[0022] The presently disclosed design for the solar array packaging and deployment addresses many of the shortcomings of the conventional systems. In the presently disclosed design, the two array wings are stowed underneath the bottom panels of a stackable satellite primary structure to provide a highly compact stowed configuration. Also, in this configuration, the arrays and satellite primary structure are able to expand to consume the launch vehicle fairing volume previously consumed by the z-folded panel width. The larger arrays provide higher power and the larger primary structure provides higher surface area for payload mounting and payload thermal dissipation. Additionally, this design can include a hinge mechanism which provides two deployment motions. The first motion allows the panel stacks to pivot from underneath the satellite structure to the side of the satellite structure. The second motion then allows the solar panel stacks to unfurl to their fully deployed configuration. Further, this can include structural design such that the bottom of the spacecraft can be dedicated towards the stowed solar array volume, whereas typical satellite structures reserve the area beneath the satellite structure for interfacing with a launch vehicle payload adapter.

[0023] FIGS. 1 A-l C illustrate a satellite 100 that has a body 102 with solar arrays 104 (e.g., solar arrays 104a, solar arrays 104b) coupled to the body 102 in a traditional z-fold configuration. The traditional z-fold configuration is illustrated in a stowed configuration (FIG. 1A), a deploying configuration (FIG. IB), and a deployed configuration (FIG. 1C). The body 102 can be operable to receive one or more payloads 14. The payload 14 can include, but is not limited to, communication transponders, cameras, navigation receivers, scientific instruments such as magnetometers, spacecraft systems for power and control, and / or experimental technologies for testing in space.

[0024] FIGS. 2-5 illustrate the satellite 200 that has a body 202 with solar array assemblies 214 (e.g., first solar array assembly 214a, second solar array assembly 214b) coupled to the body 202, according to the present disclosure. The low-profile packaging and deployment configuration disclosed herein is illustrated with the solar array assemblies 214 in a stowed configuration (FIG. 2), the solar array assemblies 214 in partially deployed configurations (FIGS. 3-4), and the solar array assemblies 214 in a deployed configuration (FIG. 5).

[0025] The satellite 200 includes a body 202, which can be operable to receive one or more payloads 204 (e.g., payload 14). The body 202 has a top 206 and a bottom 208 opposite the top 206. Additionally, the body 202 has a first side 210 and a second side 212 opposite the first side 210. In some examples, the first side 210 and the second side 212 connect opposing ends of the top 206 and, additionally, the first side 210 and the second side 212 connect opposing ends of the bottom 208. In some examples, the body 202 of the satellite 200 is configured to receive the payload 204 on the top 206 of the body 202.

[0026] Continuing with FIGS. 2-5, one or more solar array assemblies 214 (e.g., first solar array assembly 214a, second solar array assembly 214b) are coupled to the body 202 of the satellite 200. In some examples, one solar array assembly 214 is coupled to the body 202. For example, a first solar array assembly 214a can be coupled to the first side 210 of the body 202. In some examples, two solar array assemblies 214 are coupled to the body 202. For example, as illustrated in FIGS. 2-5, a first solar array assembly 214a can be coupled to the first side 210 of the body 202 and a second solar array assembly 214b can be coupled to the second side 212 of the body 202. In some examples, three or more solar array assemblies 214 are coupled to the body 202.

[0027] Each solar array assembly 214 includes one or more solar panels 216 (e.g., solar panels 216a, solar panels 216b). In some examples, the first solar array assembly 214a includesone or more solar panels 216a. For example, the first solar array assembly 214a can include one solar panel 216a, two solar panels 216a, three solar panels 216a, or four or more solar panels 216a. In at least one example, for example as illustrated in FIG. 5, the first solar array assembly 214a includes four solar panels 216a. In some examples, the second solar array assembly 214b includes one or more solar panels 216b. For example, the second solar array assembly 214b can include one solar panel 216b, two solar panels 216b, three solar panels 216b, or four or more solar panels 216b. In at least one example, for example illustrated in FIG. 5, the second solar array assembly 214b includes four solar panels 216b.

[0028] Continuing with FIGS. 2-5, each solar array assembly 214 is configured to transition between a retracted configuration (e.g., a stowed configuration) and an extended configuration (e.g., a deployed configuration). In the retracted configuration, the solar panels 216 of each respective solar array assembly 214 are folded against the bottom 208 of the body 202. For example, the solar panels 216 may be folded into a stack and the stack abuts against the bottom 208 of the body 202. When in the retracted configuration, each of the solar panels 216a, 216b can be substantially parallel to one another. In some examples, each of the solar panels 216 can be substantially parallel to the bottom 208 of the body 202. When in the retracted configuration, the presently disclosed solar array assembly 214 can allow more and / or larger payload(s) 204 to be received by the top 206 of the body 202. Accordingly, the satellite capabilities are maximized. When in the retracted configuration, the solar array assemblies 214 do not have a width that is greater than the width of the bottom 208 of the body 202. In the extended configuration, the solar panels 216 of each respective solar array assembly 214 are expanded from a side (e.g., first side 210, second side 212) of the body 202 along a longitudinal axis (e.g., first longitudinal axis LA’, second longitudinal axis LA”). In at least one example, when the solar array assemblies 214 are in the extended configuration, the solar panels 216 are substantially linear, and there is no overlap between solar panels 216. For example, none of the solar panels 216 are folded upon another solar panel 216. Accordingly, each solar panel 216 is able to fully receive solar energy without blockage from other solar panels 216. Because the solar panels 216 of each respective solar array assembly 214 are folded against the bottom 208 of the body 202 in the retracted configuration, the solar panels 216 can have an increased width (and correspondingly an increased surface area) over panels in the conventional “z-fold” configuration. This allows each solar array assembly 214 to maximize its power harvesting capability.

[0029] For example, the solar panels 216a of the first solar array assembly 214a are folded against the bottom 208 of the body 202 in the retracted configuration (as illustrated for example in FIG. 2) and expanded from the first side 210 along a first longitudinal axis (LA’) in the extended configuration (as illustrated for example in FIG. 5). Additionally or alternatively, the solar panels 216b of the second solar array assembly 214b are folded against the bottom 208 of the body 202 in the retracted configuration (as illustrated for example in FIG. 2) and expanded from the second side 212 along a second longitudinal axis (LA”) in the extended configuration (as illustrated for example in FIG. 5). In some examples, the first longitudinal axis LA’ and the second longitudinal axis LA” are substantially parallel (e.g., coaxial). In other examples, the first longitudinal axis LA’ and the second longitudinal axis LA” are substantially parallel (e.g., not coaxial).

[0030] In some examples, each solar array assembly 214, when in the extended configuration, has a natural frequency that is more than approximately 0.15 hertz (Hz). In some examples, the first solar array assembly 214a has a natural frequency that is more than approximately 0.15 Hz when the first solar array assembly 214a is in the extended configuration. Additionally or alternatively, the second solar array assembly 214b has a natural frequency that is more than approximately 0.15 Hz when the second solar array assembly 214b is in the extended configuration.

[0031] Continuing with FIGS. 2-5, in some examples, a hinge mechanism 218 (e.g., first hinge mechanism 218a, second hinge mechanism 218b) couples each of the one or more solar array assemblies 214 to the body 202 of the satellite 200. Each hinge mechanism 218 can provide a first deployment motion and / or a second deployment motion. For example, the first deployment motion of the hinge mechanism 218 allows the solar panels 216 of the respective solar array assembly 214 to pivot from the bottom 208 of the body 202 to a side (e.g., first side 210, second side 212) of the body 202. Additionally or alternatively, the second deployment motion of the hinge mechanism 218 allows the solar panels 216 of the respective solar array assembly 214 to unfurl to the extended configuration.

[0032] For example, as illustrated in FIGS. 2-5, the first solar array assembly 214a can be coupled to the first side 210 of the body 202 by a first hinge mechanism 218a, which provides (1) a first deployment motion which allows the solar panels 216a to pivot from the bottom 208 of the body 202 to extend from the first side 210 and / or (2) a second deployment motion which allows the solar panels 216a to unfurl to the extended configuration. In at least one example, when thehinge mechanism 218a provides the first deployment motion, the plurality of solar panels 216a are folded. In at least one example, when the hinge mechanism 218a provides the first deployment motion, the plurality of solar panels 216a are substantially perpendicular to the longitudinal axis LA’. In the extended configuration, each solar panel 216a is extended to be substantially parallel to the longitudinal axis LA’. Additionally or alternatively, the second solar array assembly 214b can be coupled to the second side 212 of the body 202 by a second hinge mechanism 218b, which provides (1) a first deployment motion which allows the solar panels 216b to pivot from the bottom 208 of the body 202 to extend from the second side 212 and / or (2) a second deployment motion which allows the solar panels 216b to unfurl to the extended configuration. In at least one example, when the hinge mechanism 218b provides the first deployment motion, the plurality of solar panels 216b are folded. In at least one example, when the hinge mechanism 218b provides the first deployment motion, the plurality of solar panels 216b are substantially perpendicular to the longitudinal axis LA”. In the extended configuration, each solar panel 216b is extended to be substantially parallel to the longitudinal axis LA”.

[0033] The embodiments shown and described above are only examples. Even though numerous characteristics and advantages of the present technology have been set forth in the foregoing description, together with details of the structure and function of the present disclosure, the disclosure is illustrative only, and changes may be made in the detail, especially in matters of shape, size and arrangement of the parts within the principles of the present disclosure to the full extent indicated by the broad general meaning of the terms used in the attached claims. It will therefore be appreciated that the embodiments described above may be modified within the scope of the appended claims.

Claims

CLAIMSWhat is claimed is:

1. A solar array assembly comprising: a plurality of solar panels; and a hinge mechanism operable to couple the plurality of solar panels with a side of a body of a satellite, the hinge mechanism operable to transition the plurality of solar panels between an extended configuration and a retracted configuration, wherein in the extended configuration, the plurality of solar panels are expanded from the side of the satellite along a longitudinal axis, wherein in the retracted configuration, the plurality of solar panels are folded against a bottom of the body.

2. The solar array assembly of claim 1, wherein the hinge mechanism is operable to provide a first deployment motion which allows the plurality of solar panels to pivot from the bottom of the body to the side.

3. The solar array assembly of claim 2, wherein the hinge mechanism is operable to provide a second deployment motion which allows the plurality of solar panels to unfurl to the extended configuration.

4. The solar array assembly of claim 2, wherein when the hinge mechanism provides the first deployment motion, the plurality of solar panels are folded.

5. The solar array assembly of claim 4, wherein when the hinge mechanism provides the first deployment motion, the plurality of solar panels extend substantially perpendicular to the longitudinal axis.

6. The solar array assembly of claim 1, wherein in the extended configuration, the solar array assembly has a natural frequency greater than about 0.15 hertz.

7. A satellite comprising: a body having a top, a bottom opposite the top, and a first side and a second side connecting opposing ends of the top and the bottom; a solar array assembly coupled to the first side, the solar array assembly including a plurality of solar panels, wherein in an extended configuration, the plurality of solar panels are expanded from the first side along a longitudinal axis, wherein in a retracted configuration, the plurality of solar panels are folded against the bottom of the body.

8. The solar array assembly of claim 7, wherein the hinge mechanism is operable to provide a first deployment motion which allows the plurality of solar panels to pivot from the bottom of the body to the side.

9. The solar array assembly of claim 8, wherein the hinge mechanism is operable to provide a second deployment motion which allows the plurality of solar panels to unfurl to the extended configuration.

10. The solar array assembly of claim 8, wherein when the hinge mechanism provides the first deployment motion, the plurality of solar panels are folded.

11. The solar array assembly of claim 10, wherein when the hinge mechanism provides the first deployment motion, the plurality of solar panels extend substantially perpendicular to the longitudinal axis.

12. The satellite of claim 7, wherein in the extended configuration, the solar array assembly has a natural frequency greater than about 0.15 hertz.

13. The satellite of claim 7, further comprising a second solar array assembly coupled to the second side, the second solar array assembly including a plurality of second solar panels, wherein in an extended configuration, the plurality of second solar panels are expanded from the secondside along a longitudinal axis, wherein in a retracted configuration, the plurality of second solar panels are folded against the bottom of the body.

14. The satellite of claim 13, wherein the second solar array assembly is coupled to the second side by a second hinge mechanism, wherein the second hinge mechanism is operable to provide a first deployment motion which allows the plurality of second solar panels to pivot from the bottom of the body to the first side15. The satellite of claim 14, wherein the second hinge mechanism is operable to provide a second deployment motion which allows the plurality of second solar panels to unfurl to the extended configuration.

16. The solar array assembly of claim 14, wherein when the second hinge mechanism provides the first deployment motion, the plurality of second solar panels are folded.

17. The solar array assembly of claim 16, wherein when the second hinge mechanism provides the first deployment motion, the plurality of second solar panels extend substantially perpendicular to the longitudinal axis.

18. The satellite of claim 13, wherein in the extended configuration, the second solar array assembly has a natural frequency greater than about 0.15 hertz.

19. The satellite of claim 7, further comprising a payload configured to be received by the body.

20. The satellite of claim 19, wherein the body is operable to receive the payload on the top.

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