1. Deployable Solar Array - Mission to Mars G1:3
TEAM: Daniel Bain, Craig Patton, Andrew Tendean
ADVISOR: Dr. Adeel Khalid
ISYE 4803 Spring 2019
PROBLEM STATEMENT
DESIGN, ANALYSIS & OPTIMIZATION
CURRENT SOLAR  TECHNOLOGY
AIAA request-for-proposal for a deployable solar array for a manned mission to mars. Array will provide 250kW of power for the onboard equipment of the spacecraft. Structure must be hinge less, deployed autonomously and survived the launch and deployed parameter described in the RFP.
Existing Space Mission Solar Array 
Thickness
Silicone Base(Mfg: SpectroLab, Tecstar)
50-200μm​
High Efficiency Silicone Base  (Mfg: ASE, Sharp)
76μm​
Single Junction Ga-As   (Mfg: SpectroLab, Tecstar)
μm​
Dual Junction  (Mfg: SpectroLab, Tecstar)
Triple Junction   (Mfg: Emcore, SpectroLab, Tecstar)
MATERIAL SELECTION
2040 Theoretical Model
In-Situ Vapor Deposited Parylene Substrate Solar Cells
Thickness: <1.3um
Mass per unit surface area: 3.6 g/m^2
Power output per unit surface area: 21.6W/ m^2
Endurance: 100,000 h (11 years) at 220c in vacuum environment
Parylene- C (poly-chloro-p-xylylene) Substrate
2020 Deliverable Model
MicroLink’s Epitaxial Lift-Off (ELO) Photovoltaic Cells
Thickness: <40 um
Mass per unit surface area: 250 g/m^2
Power output per unit surface area: 250 W/ m^2
Both models use Nitinol wire and electric current to unfold the solar arrays.
2020 Model – Dynamic Harmonic Analysis of 1G at 1.5 Hz (Mesh)
Spacecraft Mission Profile
System Block Diagram
DESIGN REQUIREMENTS
2020 Model – Dynamic Harmonic Analysis of 1G at 1.5 Hz (Stress)
MATERIAL COMPARISONS
Common Sheet Thickness 
Thickness
Standard Aluminum Foil
16 μm​
Standard weight Printing Paper
24 μm​
Standard Weight Plastic Wrap
12.5μm​
Mylar Space Blanket
15μm​
Deployed 2020 Model
AIAA Given RFP Requirements
FINAL DESIGN SPECIFICATIONS
Updated RFP (March 26th)
250 kW is total power supplied by multiple arrays
Each array will be limited to 9.5 kW because of solar flux
Stowed volume is for an individual array
2020 Model – Dynamic Harmonic Analysis of 1G at 1.5 Hz (Displacement)
SOLUTION PROPOSAL
Multiple-array configuration to reach target output of 250KW with each array subjected to 1.5 m radius limit and utilizing Nitinol wires as a deploying mechanism. With today’s current technology, the thinnest photovoltaic cells in production for space missions are 40um thick​. Therefore the Technology Readiness Level (TRL) for this project is at Level 1.  The team prepared two separate models.
2040 Model
This model will specify technology requirements to meet RFP requirements, as current technology cannot satisfy them
In-situ Vapor deposited Parylene Substrate Organic Photovoltaic Cells
Will satisfy deployed radius and volume requirements
2020 Model
This model will use current technology and attain as many RFP requirements as possible
MicroLink’s  epitaxial lift-off (ELO) solar cells
Will satisfy deployed radius requirement, and will not contain hinges
Volume will be a minimum while using current solar cell technology
Ability to operate after small impact
Satisfy launch and deployed vibrational analysis
Folded 2020 Model
PROTOTYPE
2020 Model – Dynamic Harmonic Analysis of 15G at 100 Hz (Mesh)
2020 Model – Closeup of Folds at Center
Materials Used:
Mylar Space Blanket (12.3 microns)
Black Plastic Sheeting (50 microns)
Clear Tape
Made as close as possible to size of 2020 Model
2020 Model – Dynamic Harmonic Analysis of 15G at 100 Hz (Stress)
Note: No damage because of incomplete SolidWorks material data