Spacecraft Solar Array Tensioning for Reliable Large-Scale Deployment
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Solution Overview
Problem
Existing technologies have not effectively addressed the challenges of scalability, reliability, and cost in spacecraft solar arrays, particularly in the larger array sizes needed to satisfy future industry and private industry needs.
Innovation Solution
A solar array system comprising a solar array blanket portion moveable from a stowed configuration into a deployed configuration, an extendable frame coupled to the spacecraft and the blanket portion and moveable from at least a collapsed configuration into an extended configuration, and at least one biasing member extending across an exterior portion of a first hinge assembly to bias the extendable frame into the deployed configuration.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If rigid panel arrays are used with accordion-folded composite plates, then deployment reliability is improved, but mass efficiency and scalability deteriorate
Solution Approach 1:
The patent employs flexible blanket solar arrays instead of rigid panels, using thin-film photovoltaic cells stretched over a tensioned membrane structure. This flexible approach dramatically reduces mass compared to rigid accordion-folded panels while maintaining deployment reliability through the tensioned frame structure that holds the blanket in place.
Solution Approach 2:
The patent uses a deployable truss structure that transitions from a compressed stowed configuration to an extended deployed configuration. This dynamic structure allows the solar array to be compact during launch and fully extended in orbit, achieving both mass efficiency and large surface area for power generation.
2Power
If solar array size is increased to meet future power needs, then power output is improved, but packaging efficiency and mass efficiency deteriorate
Solution Approach 1:
The patent designs the solar array to nest within itself and the spacecraft body during stowage. The flexible blanket folds around the truss structure, and the entire assembly compacts to fit within the launch vehicle fairing. This nested configuration enables large solar arrays to be packaged in small volumes for launch, then deployed to large sizes in orbit for high power output.
3Reliability
If traditional compression column structure is used for flexible blanket arrays, then deployment is enforced, but cost and structural complexity increase
Solution Approach 1:
The patent extracts the compression column from the traditional flexible blanket array design and replaces it with a tensioned truss structure. The truss uses tension members instead of compression members, fundamentally changing the structural approach while maintaining deployment enforcement through the tensioned geometry of the extended truss.
Solution Approach 2:
The patent replaces the mechanical compression column system with a tensioned truss system that uses cable-like members. This substitution simplifies the structure by eliminating the need for rigid compression columns and complex joint mechanisms, reducing both cost and structural complexity while maintaining deployment reliability.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The system improves reliability, maximizes power output, minimizes complexity, and reduces cost by enhancing the scalability and efficiency of spacecraft solar arrays.
Implementation Method 1
the biasing member is compressed between the first and second distal ends of the first and second support arms when the extendable frame is in the collapsed configuration
Data Source
AI summary
A solar array system associated with a spacecraft includes a solar array blanket portion moveable from a stowed configuration into a deployed configuration, an extendable frame coupled to the spacecraft and the blanket portion and moveable from at least a collapsed configuration into an extended configuration to move the solar array blanket portion from the stowed configuration into the deployed configuration, and at least one biasing member extending across an exterior portion of a first hinge assembly that is configured to bias at least a portion of the extendable frame into the deployed configuration.