Upload
evelyn-stewart-palmer
View
218
Download
3
Embed Size (px)
Citation preview
DINO Peer Review April 21, 2023
Mechanisms
Shilling, Tim
Martinez, Michael
Colorado Space Grant Consortium 2
DINO Peer Review April 21, 2023
IntroductionIntroduction
• Mechanisms includes restraints and release for:– COMM Antennas– Aerofins– FITS thin film solar arraysThe mechanisms will release the deployables in a predetermined
order– Tip mass– Antennas– FITS– Aerofins
• The restraint mechanisms are based around Planetary Systems’ Lightband, Starsys’ HOP (High Output Paraffin Actuator) and TiNi Aerospace’s Frangibolt
Colorado Space Grant Consortium 3
DINO Peer Review April 21, 2023
Requirements Imposed on Mechanisms
• Must retain mechanisms in a failsafe manner• Must release the deployables in a reliable
fashion• Must release the deployables in the order
discussed on the previous slide • Must meet power and thermal requirements
Colorado Space Grant Consortium 4
DINO Peer Review April 21, 2023
Requirements Imposed on Others• 6 Hi/Low lines to signal different stages of deployment
– Aerofins Released: 2– FITS Released: 2– Boom Released: 1– Antenna Released: 1
• 1 HOP requiring 18W at 28V for 1.5-2 minutes– Antenna Release
• Lightband separator requiring 10W @ 12V for 1 minute (May Change) – Tip Mass Release
• 4 Frangibolts 25W @ 28V for 30 Sec– FITS and Aerofins
• 4 composite hinges requiring 10W @ 28V for 1 minute– Two per Aerofin– Two Aerofins
• Thermal control of composite hinges (maintain hinge temperature between 88 and 92 deg. Celsius by cycling power to hinges)
– Minimum of two controls, one per aerofin– Requires data lines for two thermal couple (Sampling once per second)
Colorado Space Grant Consortium 5
DINO Peer Review April 21, 2023
Lightband
• 15 inch motorized separation system
• Delta V = 2 ft/s• m ≈ 6.5 lbm• Tip-off rate < 1º/s• Flight proven
– Deployed Starshine-3 satellite from Athena launch vehicle in 2001
Colorado Space Grant Consortium 6
DINO Peer Review April 21, 2023
Thin Film Solar Array (FITS)Thin Film Solar Array (FITS)
Responsibility
Microsat
• FITS
• Restraint Panel
• Deployment Hinges
CSGC
• Restraint/release system hardware
General
• Provided by Microsat
• Released with the in-house release system (IRS)
• Preloaded to 100lb
• Upon Release deployment is almost instantaneous
Colorado Space Grant Consortium 7
DINO Peer Review April 21, 2023
Flow Chart - FITS
Input and Control
Frangibolt 125 watts @ 28V
High/Low output(Switch signaling final
released position)
Frangibolt 225 watts @ 28V
High/Low output(Switch signaling final
released position)
Colorado Space Grant Consortium 8
DINO Peer Review April 21, 2023
FITS System - Stowed Stowed Solar Array Envelope
(0.318 x 0.184 x 0.033 m)Volume = 0.0019 m3 / Wing
(0.067 ft3) / Wing
Deployment Hinge
Restraint Panel
Separation Device
Colorado Space Grant Consortium 9
DINO Peer Review April 21, 2023
Deployed driving requirements - Power - 13 Vdc and 60 Watts @EOL
Deployed Solar Array1.10 m2 / Wing Fold Integrated Thin Film Stiffener (FITS) Stainless Steel CIGS Array
85 Watts BOL - AMODeployed Solar Array Meets All Requirements
1.257 m
0.439 m0.439 m
1.636 m
FITS System - DeployedFITS System - Deployed
Colorado Space Grant Consortium 10
DINO Peer Review April 21, 2023
Frangibolt
Colorado Space Grant Consortium 11
DINO Peer Review April 21, 2023
Specifications
Colorado Space Grant Consortium 12
DINO Peer Review April 21, 2023
AerofinsAerofinsGeneral
•2 Composite panels
•Solar Arrays mounted to Panels
•Deployed with 4 composite hinges from CTD
•Held down by Frangibolts
•Deployed separately
Responsibility
CTD
• Composite aerofins
• Composite Hinges
(With Mounts)
• Ability to interface with Restraint/release system hardware
CSGC
• Restraint/release system hardware
Colorado Space Grant Consortium 13
DINO Peer Review April 21, 2023
Flow Chart - Aerofins
Input and Control
Aerofins
Frangibolt 125 watts @ 28V
Composite Hinges10 watts @ 28V per Hinge for 1 minute
2-4 Hinges required
High/Low output(Switch signaling final
deployed position)
High/Low output(Switch signaling final released position) and
turns off Frangibolt
Colorado Space Grant Consortium 14
DINO Peer Review April 21, 2023
Composite Hinges
• Provided by Composite Technology Development (CTD)• Rigid in cooled State• When Heated returns to Original Shape• 4 composite hinges requiring 10W @ 28V for 1 minute
Colorado Space Grant Consortium 15
DINO Peer Review April 21, 2023
Aerofin Deployment / Stabilization
Major Cone
Major Cup
Aerofin
Minor ConeMinor Cup
Side Panel
Frangibolt Housing
Colorado Space Grant Consortium 16
DINO Peer Review April 21, 2023
Iso~Grid Mounting
•Minimal reduction in Iso~Grid strength.
•Central Cup spreads load stress over wider area, reducing flex on Aero~Fin.
•“Four Point” minor cones provides horizontal & vertical stabilization.
Colorado Space Grant Consortium 17
DINO Peer Review April 21, 2023
Cup Cones
Colorado Space Grant Consortium 18
DINO Peer Review April 21, 2023
Central Cup & Actuator Housing
•Frangi~Bolt Actuator captive in housing.
•Two Disc Springs to absorb energy of Frangi~Bolt Release.
• All Materials 6061 AL
Colorado Space Grant Consortium 19
DINO Peer Review April 21, 2023
Central Cone
•Two Piece Mount (6061 Al) w/ one Disk Spring to absorb energy of Frangi~Bolt Release
•Disk Spring transmits energy to rear plate, which spreads force over wider area, reducing shock to Aero~Fins.
•Cone material:Delrin 500
Colorado Space Grant Consortium 20
DINO Peer Review April 21, 2023
Disk Spring Data
Size & deflection are two Major advantages vs. conventional Spring.
Three Spring Disk @ 0.240in vs. Two standard springs @ 2.000in
Colorado Space Grant Consortium 21
DINO Peer Review April 21, 2023
Antenna Release System - HOP
• Pin Puller• Less then 120g• 50 lbs of force• One HOP releases
Antennas• Total travel of HOP release
Pin: .3in• Activated with 28V at 18 watts for 2 minutes,
which heats up the wax inside the piston, expanding
it and causing the pin puller to move
Colorado Space Grant Consortium 22
DINO Peer Review April 21, 2023
Testing Plan - Aerofins
Aerofin Structure
Sled Air table
CTD Hinge
StructureAir table
Sled
Colorado Space Grant Consortium 23
DINO Peer Review April 21, 2023
Testing Plan - Release System
• Fit test
•Composite hinges
•Structural
•Fangibolt
• Hanging Weight test
• Preloading
• Shock absorption
• Damage to Hinges?
• Environment
• Warm hinge release system deployment
AerofinStructure
SledAir table
CTD Hinge
Structure
Air table
Colorado Space Grant Consortium 24
DINO Peer Review April 21, 2023
Parts ListIn-House
•Testing equipment
•FITS
•Aerofins
•Release system
•Outsourced springs
•Aluminum parts
Outsourced
•Aerofins: Free
•HOP: Free
•FITS: Free
•Arrays
•Hinges
•3 Fringebolt: Free
•Actuator
•6 bolts: $100 each
•Reset Tool: TBD
•Tip mass
•Lightband
•Tether
Colorado Space Grant Consortium 25
DINO Peer Review April 21, 2023
Issues and Concerns (Things to be done)
• To get to CDR– Complete Prototyping
• How did the Release systems perform
– Testing to insure functionality, at least in std atmospheric conditions
– Antenna release design– Documentation– Fits release system, How does Microsat want to deal
with the Frangibot?
DINO Peer Review April 21, 2023
Structures
Shilling, TimMcArthur, GraysonSchumacher, Ted
Ko, PaulJones, Robert
Colorado Space Grant Consortium 27
DINO Peer Review April 21, 2023
IntroductionIntroduction
• Structures is to interface and house all components onto a common chasse.
• Structures will protect components from the space and launch environment, including but not limited to vibration, impact and radiation hazards.
• Structures is to interface to the ICU via Lightband as well as provide interface for the Tip mass.
• Structures will provide casing and structural connection for all components (Electronics, batteries, solar arrays, ect.)
Colorado Space Grant Consortium 28
DINO Peer Review April 21, 2023
Requirements Imposed on Structures
• Entire Structure with mechanisms will be less then 9.19 Kg
• Fixed base Natural Frequency > 100Hz at the Shuttle interface plane (SIP).
• Center of mass is to be no more then .25in from centerline and 12in from the SIP.
• Structural Ground will be isolated from Electrical Ground
• Structure must be electrically continuous (less then 1 ohm resistance)
• Structure will be coated to ensure against electrical shorting
• The completed satellite must fit within ICU envelope
• Structures must provide enclosures (As necessitated) and structural support to all electrical components.
• Structures must provide mounting for surface mounted solar arrays, aerofins, FITS and antennas (As necessitated)
• Meet all Safety concerns applicable to shuttle flight
Colorado Space Grant Consortium 29
DINO Peer Review April 21, 2023
Requirements Imposed on Others
• All systems will meet allocated size and mass budgets
• No component may have a width > 8.5in or a height > 11in
• Components may not be greater then 2in deep without prior approval from Structures and Systems
Colorado Space Grant Consortium 30
DINO Peer Review April 21, 2023
ICU Envelope
Colorado Space Grant Consortium 31
DINO Peer Review April 21, 2023
Exploded View
FITS Aerofins Power Panel
COMM
Cameras
C&DH + ADCS
Antenna Release
Colorado Space Grant Consortium 32
DINO Peer Review April 21, 2023
Main Structure
• Mass: 3.52kg• Height:12.25in • Diameter: 17.32in• Material: Al 6061• Similar design to Three
Corner Satellite
Colorado Space Grant Consortium 33
DINO Peer Review April 21, 2023
Nadir Plate
• Iso-Grid Design• Mounting plate for
Lightband systems
Colorado Space Grant Consortium 34
DINO Peer Review April 21, 2023
Side Panels
Colorado Space Grant Consortium 35
DINO Peer Review April 21, 2023
Finite Element Analysis
• Analyze the Isogrid structure to get an idea of its performance before building a test specimen.
• Examine the trade off between total mass and stiffness
• Requirements– Stiffness: Fundamental frequency > 100 Hz.– Withstand a 20 G force in each direction
Colorado Space Grant Consortium 36
DINO Peer Review April 21, 2023
Model Details
• Global size = 3.0328 mm• Tolerance = 0.15164 mm• Touching faces bonded• Material: Al 6061 linear elastic isotropic• Jacobian 4pt check• Restraints set as immovable (no translation)• Restraints located at each of the 8 mounting wholes• 20 G force acting through the center of gravity
Colorado Space Grant Consortium 37
DINO Peer Review April 21, 2023
General Drawings
Isogrid side
Back of panel
Isogrid with Outer PlateIsogrid
Colorado Space Grant Consortium 38
DINO Peer Review April 21, 2023
Design Options• Option 1
- 0.25 in. thick panel with no outer plate- mass = 0.339 kg- Stiffness = 278.16 Hz.
• Option 2- 0.125 in. thick panel with no outer plate- mass = 0.170 kg- Stiffness = 147.59 Hz.
• Option 3- 0.20 in. thick panel with 0.05 in. thick outer plate- mass = panel + outer plate = 0.272 + 0.223 = 0.495 kg - Stiffness = 295.71 Hz.
• Option 4- 0.075 in. thick panel with 0.05 in thick outer plate- mass = panel + outer plate = 0.102 + 0.223 = 0.325 kg- Stiffness = 139.95 Hz.
Colorado Space Grant Consortium 39
DINO Peer Review April 21, 2023
Chosen Design
• Option 1
- 0.25 in. thick panel with no outer plate
- mass = 0.339 kg
- Stiffness = 278.16 Hz.
• Offered the best trade off between mass and stiffness.
• Easy to manufacture because one does not have to worry about leaving an outer wall.
Colorado Space Grant Consortium 40
DINO Peer Review April 21, 2023
Analysis
• Stress calculated for a 20 G force acting solely in one of the three axis
• Stress calculated in von Mises stress (N/m^2)• Design check plot generated for FOS of 2 based
on stress• The stress plots also resemble the scaled
deformed shape
Colorado Space Grant Consortium 41
DINO Peer Review April 21, 2023
Plots for Y DirectionStress Design Check
Red < FOS = 2 < Blue
Colorado Space Grant Consortium 42
DINO Peer Review April 21, 2023
Plots for X DirectionStress Design Check
Red < FOS = 2 < Blue
Colorado Space Grant Consortium 43
DINO Peer Review April 21, 2023
Plots for Z DirectionStress Design Check
Red < FOS = 2 < Blue
Colorado Space Grant Consortium 44
DINO Peer Review April 21, 2023
Plot Interpretation
• All of the design check plots show the entire panel in blue, meaning that all areas equal or exceed a factor of safety equal to 2
• These two types of plots prove the side panel will withstand the 20 G forces
Colorado Space Grant Consortium 45
DINO Peer Review April 21, 2023
Issues and Concerns
• Meshing the structure as a whole, including all side panels, top and bottom plates. Several attempts have been made with multiple problems.
• How to simulate the boxes attached to the structure.– Point mass or Sheet mass
Colorado Space Grant Consortium 46
DINO Peer Review April 21, 2023
Drawing Package
Colorado Space Grant Consortium 47
DINO Peer Review April 21, 2023
ADCS + C&DH Box Design
Colorado Space Grant Consortium 48
DINO Peer Review April 21, 2023
Camera Box Pieces
Outer Box-Holds camera at ? deg angle -Allows access to USB port and power supply-Protects circuit board-- 1/8 in. thick walls
Camera Bracket
-Secures camera in box
-Supports circuit board
*** Revision A, Awaiting
Final Camera Selection
Colorado Space Grant Consortium 49
DINO Peer Review April 21, 2023
Complete Camera Box
Full assembly of camera box
Complete Assembly-Encloses camera
-Mounts to earth facing plate
-Holds camera at 30deg angle
-Manufacturing done as a short component
Colorado Space Grant Consortium 50
DINO Peer Review April 21, 2023
Comm Box
• Use already designed and
tested box• Mounting plate allows
connection to Satellite isogrid.• Constructed of Al6061
and anodized• TNC?
Colorado Space Grant Consortium 51
DINO Peer Review April 21, 2023
Environmental Analysis
Colorado Space Grant Consortium 52
DINO Peer Review April 21, 2023
The Harsh Environment
• Protection Against: – Atomic Oxygen (AO)– High Energy Protons and
Electrons– Debris and Micrometeors– Radiation
• The Toughest Opponent at ISS orbit
Colorado Space Grant Consortium 53
DINO Peer Review April 21, 2023
Atomic Oxygen
• Increases with the angle of incidence with Earth• Decays material in direct contact
– The rate of decay is negligible– AO is only a design factor to account for when the mission
duration is over a couple years
Colorado Space Grant Consortium 54
DINO Peer Review April 21, 2023
High Energy Protons and Electrons
• Only affects the outer region of the satellite
• A thin layer of material stops the damage
• The inflicted amount of decay is negligible over the 6 month mission
Colorado Space Grant Consortium 55
DINO Peer Review April 21, 2023
Debris and Micrometeors• Material travels at high velocity• The impacts are on the scale of a few centimeters• These impacts would not infringe upon the satellites
operation
Colorado Space Grant Consortium 56
DINO Peer Review April 21, 2023
Radiation Factors
• Solar Activity Cycle• Trapped Protons• Galactic Cosmic
Radiation• Solar Flare Protons• Solar Flare Heavy
Ions• Inner Zone Electrons
Colorado Space Grant Consortium 57
DINO Peer Review April 21, 2023
Solar Activity Cycle
• The Sun has a 22 year cycle• The cycle was at the 50 year Mauder Minimum in the year
2000• The mission will be launched in 2005• The Solar Cycle reaches a minimum in 2006
• The Sunspot Cycle will be low
Colorado Space Grant Consortium 58
DINO Peer Review April 21, 2023
Colorado Space Grant Consortium 59
DINO Peer Review April 21, 2023
Unimportant Factors
• Solar Flare Protons • Solar Flare Heavy
Ions– Only occur during
Solar Maximum
Colorado Space Grant Consortium 60
DINO Peer Review April 21, 2023
ISS orbit Protection
• Inner Zone Electrons • Trapped Protons
– Not a design factor • Altitude of mission
is much lower than where these two factors cause damage
Colorado Space Grant Consortium 61
DINO Peer Review April 21, 2023
Galactic Cosmic Radiation
• High velocities strip the atoms of their nucleus• Varies with the solar cycle• At a maximum during the Solar Minimum
– At a maximum during the missions duration
Colorado Space Grant Consortium 62
DINO Peer Review April 21, 2023
Colorado Space Grant Consortium 63
DINO Peer Review April 21, 2023
Galactic Cosmic Radiation
• Not a factor due to the low ISS orbit of 4000km
• Mainly attacks DNA– Very harmful to
manned missions
Colorado Space Grant Consortium 64
DINO Peer Review April 21, 2023
Recommendations
• To stop radiation
– Use the .25 in thick aluminum
• To guard against Micrometeors, AO, Debris, high and low temperatures and High Energy Protons and Electrons
• Use the MLI blanket
Colorado Space Grant Consortium 65
DINO Peer Review April 21, 2023
Conclusion
• The damaging effects of the environment are suppressed with the MLI blanket
• The Radiation is suppressed by the aluminum wall
• The satellite will function properly
Colorado Space Grant Consortium 66
DINO Peer Review April 21, 2023
Early Testing
• FEA– Based on CAPE requirements– Guidance provided in UN-SPEC-12311, Stress Analysis Guidelines.
• Envelope Verification• Mass Properties• Center of Gravity• Design checks and manufacturing checks• Check fits of every component as it is manufactured and returned
from outsourced processing • Pre mechanical Integration testing of all components• Electrical grounding path
– Late in assembly.– Perform after anodizing, but before components are integrated – If it is not right what should we do?
• Structural tests.
Colorado Space Grant Consortium 67
DINO Peer Review April 21, 2023
Testing Plans
Colorado Space Grant Consortium 68
DINO Peer Review April 21, 2023
Assembly Procedure
• Design Check with Designer, Maker, Team Lead and Systems
• Manufacture part• Tap all holes (Do Not Helecoil)• Check fit with hardware and structure• Part Check with Designer, Maker and Team Lead• Clean with Alcohol• Coat / Anodize
– Approve with Team Lead – All Taps plugged – Check part upon return
• Helecoil• Check Fit
Colorado Space Grant Consortium 69
DINO Peer Review April 21, 2023
Parts List
Outsourced Estimated• Fasteners: 2000 @ $.75 =
$1500• Anodizing: $500 • 6 Side panels. 9 x 12.5 x .25in
Al6061 plates:
$67 NIST• 1 Nadir Plates. 17.5 x 17
x .75in Al6061 plates:
$100 NIST• Aluminum for all casings,
boxes, ect (Look at budget for constraints)
In House• Entire structure, boxes,
mechanical interfaces and structural ground support
Colorado Space Grant Consortium 70
DINO Peer Review April 21, 2023
Budgeted
Component QuantityUnit Price
Total Price
Side Panels 15 $18.57 $278.55
Bulkheads 4 $130.00 $520.00
Boxes 30 $80.00 $2,400.00
Fastners 2000 $0.75 $1,500.00
Anodizing 1 $500.00 $500.00
Total: $5,198.55
Colorado Space Grant Consortium 71
DINO Peer Review April 21, 2023
Issues and Concerns (Things to be done)
• To get to CDR– Complete FEA
• How is the composite top panel going to effect things?
– Boxes• Design
– Need more concrete info, maybe I should have a 1 on 1 meeting with each team
• Position– Design decisions on placement to ensure box design
corresponds
– Documentation– What kind of testing should be done?
DINO Peer Review April 21, 2023
Mechanical Ground Support Equipment
The support for assembly.
Colorado Space Grant Consortium 73
DINO Peer Review April 21, 2023
Purpose
• Assist assembly of satellite.
• Allow easy integration of hardware, wiring, mechanisms, side panels.
• Allow easy transportation.• Allow easy accessibility.
Colorado Space Grant Consortium 74
DINO Peer Review April 21, 2023
Requirements
• Must be able to move through doors.
• Must allow side panels to lay out in a “flower” pattern-easy accessibility.
• Must allow rotation about one axis of at least 45 degrees.
• Must not endanger the integrity of the satellite or any of its components at any time.
Colorado Space Grant Consortium 75
DINO Peer Review April 21, 2023
Requirements Met:
• Axis enables 57 degree rotation in every direction.
• Satellite or base will each have at least five screw points and will stay attached during rotation.
• MGSE allows “flowering” of side panels.
Colorado Space Grant Consortium 76
DINO Peer Review April 21, 2023
MGSE Measurements
Colorado Space Grant Consortium 77
DINO Peer Review April 21, 2023
Colorado Space Grant Consortium 78
DINO Peer Review April 21, 2023
Parts List & Pricing
Colorado Space Grant Consortium 79
DINO Peer Review April 21, 2023
Issues and Concerns:
• Cost• Stability