European Space Agency

E3000 Second Generation Solar Array

Objectives

Within the ARTES 3 Program EUROSTAR 3000 Second Generation Solar Array EADS Astrium GmbH will:


  • Aim to enhance the product Solar Array,

  • Improve the competitiveness in the current market environment,

  • Improve at least the current satellite cost base.
by means of


  • Standardization of product,

  • Introduction of adequate level of modularity,

  • Reduction of the number of different configurations,

  • Streamlining of product.
The overall objective of the EUROSTAR 3000 Second Generation Solar Array development is to come to an electrically and mechanically qualified and standardized solar array design, which is still flexible enough to cover the extended EUROSTAR 3000 payload power requirements ranging from 4.5 up to 14 kW while meeting specific customer power requirements without an excessive mass penalty.

This can be achieved with a family of four solar arrays termed SX, S, L, LX, each of them equipped solely with GaAs cells. The SX version will use 3 panels of the short type, the S version 4 short panels, the L version 4 long panels and the LX version 5 long panels. This will match the EUROSTAR 3000 payload power requirements. Specific power requirements within each class can be met by not completely populating the innermost panel of each solar array wing.


EUROSTAR 3000 Solar Array



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Challenges

The EUROSTAR 3000 Second Generation Solar Array will be a design which goes into the direction of aims at series production. The EUROSTAR 3000 Second Generation Solar Array builds fully on the existing design, but concentrates on the areas that were identified for improvement. More specifically, the modifications foreseen for the EUROSTAR 3000 Second Generation Solar Array are listed below. These are based on the lessons learned from the EUROSTAR 3000 programmes, and on the need to adapt to changing markets.
Qualification of a new mechanical design which involves:


  • Design and analysis for all 4 versions with the aim to achieve a common design for all individual panels to the extend appropriate, i.e. as long as it contributes to the overall cost efficiency of the design,

  • Standardisation of inserts, brackets, thermal fins and other smaller parts,

  • Qualification on parts level for yoke, ADCS flap, Closed Cable Loop and implementation of the Low Shock Release unit (LSRU),

  • Qualification of the design on 2 solar array wings.
Qualification of a new electrical design which involves:

  • Design of a new common electrical layout with 100% GaAs cells,

  • Qualification of GaAs Solar Cell Assembly,

  • Various coupon tests, e.g. to test a new cell repair method,

  • Improvement of the transfer harness to simplify the design and to have a common harness layout for all different versions,

  • Ion propulsion resistant design of exposed materials,

  • Various smaller component improvements,

  • Qualification of the design on 2 solar array wings (the same as those mentioned above).
These changes will be qualified on parts level and by means of qualification testing of two solar array wings: one with long panels, and one with short panels.

Benefits

The main benefits for EADS Astrium GmbH from the EUROSTAR 3000 Second Generation Solar Array project are:


  • Maintain, control, continuously improve and standardize the EUROSTAR 3000 Platform,

  • Streamline the catalogue of product options,

  • Build an EADS Astrium platform around a single EUROSTAR3000 core platform product,

  • improve the competitiveness in the current market environment reduce the Solar Array cost.

Features

The present EUROSTAR 3000 solar array features a rigid maximum 5 panel fold out Solar Array with the addition of an ADCS flap for attitude control of the spacecraft with the help of solar pressure. Mechanically there are two different versions of the solar array panel:
Short version - panel size of 3.050 x 2.28 m
Long version - panel size of 3.915 x 2.28 m.

EUROSTAR 3000 Second Generation is prepared to cover the following Payload Power Classes:



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Plan

In the above shown chart the development and qualification philosophy for the EUROSTAR 3000 Second Generation Solar Array is shown. After finalization of the two main design and development paths, improvement of mechanical and electrical design, the wing design files will be created and than the PFM Sequence will be performed and the hardware will be flown.



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Current status

The EUROSTAR 3000 Second Generation Solar Array project has started. The BDR is dated for September 2004. The BDR data package has been provided to ESA. For all components to be improved and qualified dedicated design specifications have been issued. The standardized layout for the Version L and Version S panel frontside is finalized. The YOKE design qualification activities for the Version L is nearly finished. The mechanical FEM analyses for the Version L have been performed.

Status date

Wednesday, November 23, 2011 - 13:10