Constellation Array Design and Analysis Study

ABSTRACT: EELV-class launches cost $100M-$300M, so there is enormous cost-saving to reduce the total number of launches needed for a constellation. In many cases solar arrays prohibit multiple spacecraft per launch. The performance of rigid panel arrays is not sufficient. Blanket arrays are the solution, as blankets have very light substrates and fold very compactly. UltraFlex and ROSA arrays offer near-term solutions, with increased metrics for packaging efficiency and mass, but each has limitations we believe can be surpassed by a new concept: The Compact Telescoping Array (CTA). A recently-published, government-funded design study has conceptualized and evaluated CTA based on existing technologies z-folded blankets deployed by a telescoping boom which promises high strength, high compaction, and ultra-light performance. Our assessment supports the potential to achieve breakthrough performance and cost savings, with a minimum of development cost and risk. This proposed SBIR activity will enable the maturation of this system capability to enable spacecraft multi-launch configurations and near-term mission infusion. It is our expectation that the completion of Phase II activity would culminate with the capability for a CTA to be proposed for the next GPS constellation and other flight missions, with the equivalent of near-TRL 6 (at the subsystem level). ; BENEFIT: Successful completion of the Phase I program will result in detailed design development and understanding of CTA performance for the GPS dual-launch application, a CTA demonstration model, and the comparative performance of UltraFlex for the same GPS requirements. The work will serve to ground and validate our recommendations for the best wing for a given application and will define the exact nature of required further development efforts for CTA. A Phase II program would focus on further advancing CTA technology and will include the prototyping of critical new subsystems at high fidelity, such as the top panel folding hinge among other areas requiring hardware development. Phase II tasks would likely include, 1) Detailed design of all subsystems and components from the Phase I models, 2) Additional finite element analysis on selected components and subsystems to determine optimal designs, 3) Manufacture of prototypes of selected subsystems and components to further reduce risk for the few areas of the design that lack significant flight heritage, 4) Manufacture of a scale model of a CTA wing, and 5) Preparation for manufacture and test of a full-scale CTA wing in post-Phase II. Angstrom Designs expects that after the Phase II effort CTA will be near or at TRL 6 and will be ready for adoption by a flight program. An alternate option would be to apply for advanced development funds and build a ground test technology demonstrator and/or further advance the fidelity of critical subsystems of the CTA design in partnership with OAG. After Phase II, CTA will likely be ready for selection by a flight program. The promise of the design, the use of many flight heritage subsystems and components and a commercial partner, OAG, with significant experience in manufacturing and flying solar arrays, all enable rapid and low risk adoption of this promising new concept. Additionally, OAG is very enthusiastic about this technology. CTA would be an excellent complement to OAGs UltraFlex technology, which has a fixed, round aspect ratio. With a variable, rectangular aspect ratio and compact stowed form it could package into many situations where UltraFlex is not an ideal solution and perform as well as or better than UltraFlex for mass, stowed volume and cost. OAG recognizes the importance of diversifying their product line and sees CTA as an excellent option for mission scenarios where a high-performing rectangular blanket array is a better fit. Beyond the GPS mission, and constellation spacecraft in general, there is great interest in high-performance mid-range power solar arrays for many other applications. Orbital-ATKs civil, commercial, and defense customers and could all benefit from superior blanket array performance technology like UltraFlex and the particular advantages of promised from the CTA concept for a broad range of performance critical missions. The path to commercialization will be enabled by the broad market access provided by our partner OAG, who has significant interest in commercializing CTA technology. Post-Phase II commercialization would be in the form of sales directly from OAG. The entire space community is interested in high performance solar arrays. CTA offers great promise for mass efficiency, compact stowage, scalability to high power levels, and variability to fit different spacecraft busses and fairings. Benefits over the current state of practice will be most significant for large wings (5-10 kW), so early commercialization efforts will focus on the needs of larger satellites in higher orbits, such as MEO-orbit GPS satellites and GEO-orbit communications satellites. These applications are equally relevant for customers other than the Air Force, such as NASA and private, commercial prime contractors.