Synchronized Modular Integrated Deployable Array (P-DoD12-003)

ABSTRACT: Conventional rigid-panel solar arrays are deployed with complex mechanisms or dynamically-tuned and damped hinges, with cables or external linkages for synchronization. Altering the number or size of panels incurs significant new engineering, tooling, manufacturing and integration. This SBIR develops the Modular Advanced Synchronization Technology (MAST) deployable array that uses multi-functional panels with internal linkages that synchronize hinges having integral distributed motive force for simple, passive deployment and lock-up. The approach is fully modular and easily adaptable to different sizes of solar panels and because of the distributed deployment force, different numbers of panels per wing, reducing NRE and schedule. The development has emphasized maximum use of modified COTS parts for low cost, and high performance composites for low mass. In Phase I, we designed, analyzed and built a 3-panel demonstration which verified the hinge and synchronization approach. The Phase II builds upon these results, updating the panel-to-panel hinge design, developing the approach for a root panel hinge, hold-down and release interfaces, array deployable harness, and GSE. We fabricate a five panel array with representative structural properties, test the stowed array in launch environment, and perform hot and cold vacuum deployments to increase to TRL 5, showing readiness for flight qualification. BENEFIT: The standardization and reduced complexity of the MAST deployable array approach improves cost and reliability, key issues in all space solar array deployment, by applying a known qualified technology to a variety of array sizes and configurations. Because of its broad applicability, the approach could meet the requirements for higher performance and more cost-effective solar arrays in a variety of missions, from small spacecraft to very large ones. Reliable high power arrays at low cost could enable new spacecraft applications, including commercial space radar and earth observation platforms. The basic technology can also find commercial applications in other space deployable structures such as larger deployable antennas for commercial communication satellites, or even deployable space habitats for commercial space tourism.