Mechanisms DINO CDR March 13, 2004

Introduction Mechanisms includes restraint and release for: COMM Antennas CTD test Panel FITS thin film solar arrays Tipmass The mechanisms will release the deployables in a predetermined order Tip mass Antennas FITS CTD The restraint mechanisms are based around Planetary Systems’ Lightband, Starsys’ HOP (High Output Paraffin Actuator) and TiNi Aerospace’s Frangibolt Colorado Space Grant Consortium

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

Requirements Imposed on Others 1 Hi/Low lines to signal different stages of deployment Boom Released: 1 4 Analog outputs Monitor temps of 2 EMC Hinges, 1 HOP, and 1 Frangibolt 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 2 Frangibolts 25W @ 28V for 30 Sec FITS and CTD Panel 2 composite hinges requiring 10W @ 28V for 1 minute 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 hinge Requires data lines for two thermal couple (Sampling once per second) Colorado Space Grant Consortium

Magic Semi-Rigid Boom March 13, 2004

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

MAGIC Boom Release system to control deployment of Tip Mass, reduce rotational Inertia, and provide gradual dissipation of initial deployment energy from lightband deployment Tip-Mass Colorado Space Grant Consortium

Functional Description Boom / Tether The semi rigid tether (SRT) is constructed of 2 COTS spring metal "tape measures", six meters length by 1 in wide, curved along their width.  To be configured ‘face to face’, provides greater stability. Colorado Space Grant Consortium

Deployment System (As Configured for KC-135 Testing) Colorado Space Grant Consortium

Functional Description (cont) Deployment / Braking System The stowed SRT will be wound on two spools such that when deployed the two tape measures will be face to face, forming a rigid structure. Colorado Space Grant Consortium

Functional Description (cont) The MAGIC Tether deployment system consists of two 2.5 inch spools, geared to counter rotate and unwind the spring metal boom in a controlled manner. Colorado Space Grant Consortium

Functional Description (cont) Velocity control is provided by a 48 tooth, 2.0 inch ratchet and pawl system, with the ratchet shafted to the geared spool, and the pawl spring loaded to provide a loading / braking force against the ratchet Colorado Space Grant Consortium

System Mounting Deployment / Braking System mounted in Tip Mass Boom mounted to Main Satellite with a tether attachment system (TAZ), designed to maintain the rigid natural shape of the tether, while providing a secure attachment. Colorado Space Grant Consortium

Changes since PDR This configuration developed to replace the flexible tether discussed at PDR Provides a more stable platform for the Tip Mass Colorado Space Grant Consortium

Compliance with Design Requirements Mass / Size : Currently over mass budget (+0.9 kg) of 1.1 kg Current configuration within size requirements Power / Thermal : NONE Colorado Space Grant Consortium

Make or buy ? Gears / Ratchets to be procured, due to cost / feasibility of local manufacture Tape COTS All other parts machined locally Lower cost Better control of Quality Colorado Space Grant Consortium

Fabrication, assembly & testing Fabrication / assembly to begin when design approved Local fabrication of all manufactured parts to be in ITLL machine shop Functional testing planned for April 2004 Testing at Johnson Space Center KC-135 zero g sim flight Colorado Space Grant Consortium

Task List All Major components designed / spec Need detail drawings for machine work Mass reduction in progress Procure mfg. components ASAP Initial calculations of spring force required completed Final decision to be made after analysis of data from KC-135 flight Colorado Space Grant Consortium

FITS March 13, 2004

Thin Film Solar Array (FITS) Responsibility Microsat FITS Restraint Panel Deployment Hinges CSGC Restraint/release system hardware General Provided by Microsat Released with a Frangibolt Preloaded to 100lb Upon Release deployment is almost instantaneous Colorado Space Grant Consortium

(Switch signaling final Flow Chart - FITS Input and Control Frangibolt 1 25 watts @ 28V High/Low output (Switch signaling final released position) Colorado Space Grant Consortium

How FITS Works Colorado Space Grant Consortium FITS STIFFENERS Z-FOLD STOWED Z-FOLD TRI-FOLD DEPLOYED FITS STIFFENERS Z-FOLD DEPLOYMENT FITS SA EDU Colorado Space Grant Consortium

Solar Array Subsystem Overview Stowed Solar Array Envelope (0.381 x 0.19 x 0.033 m) Volume = 0.0024 m3 / Wing Deployment Hinges Frangibolt Sep device Restraint Panel Colorado Space Grant Consortium

Solar Array Subsystem Overview Deployed driving requirements - Power - 19 Vdc and 90 Watts @EOL Deployed Solar Array 1.14 m2 Fold Integrated Thin Film Stiffener (FITS) Stainless Steel CIGS Array Deployed Solar Array Meets All Requirements Colorado Space Grant Consortium

Frangibolt Colorado Space Grant Consortium

Specifications Colorado Space Grant Consortium

Grayson McArthur Amanda Heaton March 13, 2004 CTD Deployable Panel Grayson McArthur Amanda Heaton March 13, 2004

Objectives Deploy a panel containing a magnetometer for attitude determination and three one axis accelerometers to gather position data on the performance of the CTD. Colorado Space Grant Consortium

Design Changes One panel Two double bladed hinges One frangibolt Deploying parallel to velocity vector Gathering numerical data for CTD Colorado Space Grant Consortium

Flow Chart - CTD Panel Input and Control Aerofins High/Low output Frangibolt 1 25 watts @ 28V High/Low output (Switch signaling final released position) and turns off Frangibolt Composite Hinges 10 watts @ 28V per Hinge for 1 minute 2-4 Hinges required High/Low output (Switch signaling final deployed position) Colorado Space Grant Consortium

Requirements Requirement Method Status Relieve all loading from composite hinges during launch Design, Test Hinge needs 10W at 28V Frangibolt needs 25W at 28V Use of one entire side panel Design, Analysis Use accelerometers to gather position data for CTD Colorado Space Grant Consortium

Full Assembly Colorado Space Grant Consortium Magnetometer Accelerometers Colorado Space Grant Consortium

Mechanical Drawings Modified Side panel Colorado Space Grant Removed strut Removed strut Colorado Space Grant Consortium

Mechanical Drawings Hinge Attachment Bracket Colorado Space Grant Consortium

Mechanical Drawings Bottom Cup Colorado Space Grant Consortium

Mechanical Drawing Left Cup Colorado Space Grant Consortium

Mechanical Drawing Right Cup Colorado Space Grant Consortium

Mechanical Drawings Cone Colorado Space Grant Consortium

Frangibolt Release Execution Memory Composite 500 lbs holding force 25W @ 28V 21 seconds Increased temperature from power activates release. Colorado Space Grant Consortium

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

Mass Table Component (how many) Mass Attachment plate (1) 0.0784 kg Isogrid (1) 0.3348 kg Cone (3) 0.0115 kg Bracket (2) 0.0058 kg Straight Cup (1) 0.0100 kg Frangibolt (1) 0.020 kg EMC Hinge (2) 0.0210 kg Left/Right Cup (1 of each) 0.0101 kg Assembly 0.5515 kg Colorado Space Grant Consortium

Parts Status Part Availability Status Frangibolt unit Have one actuator and several bolts donated Outer panel Manufactured by CTD at our Discretion Will be ordering soon EMC hinge Manufactured by CTD at our discretion Colorado Space Grant Consortium

Manufacturing Isogrid panel - Manufacturing process the same as the other panels using the CNC Cups/Cones - Purchase special bits for the CNC that can cut cups and domes Adaptor plate - Cut from single sheet of 1/8 in. aluminum, use drill press for drilling attachment holes EMC Hinge and outer panel - Manufactured for us by CTD Colorado Space Grant Consortium

CTD Panel General 1 Composite panels Accelerometers and magnetometer Deployed with 2 composite hinges from CTD Held down by Frangibolt Responsibility CTD Composite panels Composite Hinges Ability to interface with Restraint/release system hardware CSGC Restraint/release system hardware Colorado Space Grant Consortium

Testing Can test actual frangibolt Frangibolt can be used repeatedly Can test actual composite hinges - Composite hinges get weaker with use Use analysis to determine if cup/cone system relieves loads from hinges Colorado Space Grant Consortium

Issues and Concerns Attachment of frangibolt to structure Running short on time Component height Task left to do - Release system finalization Colorado Space Grant Consortium

Antenna Deployment Mechanism March 13, 2004

Introduction Antenna Deployment Mechanism include Antenna deployment and positioning Antennas are mounted on a cylindrical Delrin hinge at a preset angle of 28.7 degrees with integrated torsion springs Epoxy (Raytheon 2216T or Epon 828) will be used to mount Antennas to cylinder hinge, threading is not possible with antenna cylinder thickness. Two torsion springs will be utilized at each end of the cylinder hinge Torsion springs are required to provide enough force to deploy antennas and to hold antennas 90 degrees relative to isogrid base A Delrin crossbeam will be attached to both antennas in order to utilize the Starsys’ HOP (High Output Paraffin Actuator) for timed release. Crossbeam and antenna tip mounts will eliminate unwanted vibrations during launch and assure accurate positioning of antenna Delrin is non-conductive and will decrease the weight of the system, less weight requires less force from the torsion springs Colorado Space Grant Consortium

Functional Description Antennas will be initially parallel (flush) with isogrid base with Delrin crossbeam attached to the HOP holding the antennas in place. This will cause torsion springs to recoil, preparing for deployment. For deployment the HOP will release the pin attaching the crossbeam to the base, which will cause the torsion springs to rotate the cylinder hinge and deploy the antennas to desired position. Rotation of hinge are limited to 90 degrees regardless of force from torsion springs. Torsion springs will also provide adequate force to maintain the antenna’s position perpendicular from isogrid base after antenna deployment. Colorado Space Grant Consortium

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

Function Description – Before Deployment Colorado Space Grant Consortium

Function Description - Deployed Colorado Space Grant Consortium

Changes since PDR Number of antennas have been reduced from three to two. New single antenna design will transmit and receive while the other single antenna functions as a duck Colorado Space Grant Consortium

Functional Requirements Coefficient of friction between cylinder and hinge must be relatively low. Possible use of lubricated Delrin to reduce coefficient friction Space between cylinder and hinge must accommodate changes due to temperature variations. Experiments on the hinge in a range of temperatures will be conducted in order to assure proper operation Vibration reduction of antennas during launch via Delrin crossbeam Crossbeam will be used to eliminate unwanted vibrations during launch to suppress damage to antenna assembly Torsion springs must provide enough force to rotate antenna assembly 90 degrees and keep antennas perpendicular relative to isogrid base during entire mission. Will provide the desired position of the antenna to operate efficiently Colorado Space Grant Consortium

Functional Requirements and Compliance of Design Mass requirements Antenna system including cylinder must be less than 1 lb for a spring constant of .0389 in*lb/deg. Spring constant designed for 180 degrees of operation when only 90 degrees is needed. Two springs will also be used to insure correct operation during entire mission. Power requirements 28V at 18 watts for 2 minutes for HOP operation Thermal requirements Melting point of Delrin is 347 degrees Fahrenheit Size requirements Hinge assembly must not exceed .5 inch when undeployed Colorado Space Grant Consortium

Delrin Specifications Colorado Space Grant Consortium

Major Components of Subsystem Colorado Space Grant Consortium

Major Components - Base Colorado Space Grant Consortium

Major Components – Crossbeam Colorado Space Grant Consortium

Major Component – Hinge Cylinder Colorado Space Grant Consortium

Major Component – HOP Mount Colorado Space Grant Consortium

Make or Buy Decisions and Rationale Hinge cylinder, base plate, cross beam, and HOP mount assembly will be built in-house with Delrin and Aluminum material to reduce cost and assure quality and proper operation Torsion Springs and Epoxy (Raytheon 2216T or Epon 828) are out-sourced materials. Colorado Space Grant Consortium

Parts List In-House Antenna Deployment Mechanism Testing equipment Delrin: < $40 Includes hinge cylinder, base plate, cross beam, and HOP mount Epoxy: < $10 Testing equipment Thermocouple Heat plate Outsourced HOP: Free Springs: < $10 Colorado Space Grant Consortium

Fabrication and Assembly Machining Process will begin immediately upon approval Operation testing --- undecided Colorado Space Grant Consortium

Manufacturing and Test Facility Requirements Manufacturing Requirements CAD Machine Shop CNC/ CNC lathe and mill Test Facility Requirements Solidworks FEM analysis Thermocouple and heat plate for ideal temperature conditions Colorado Space Grant Consortium

Documentation Torsion Spring Calculation Delrin Specifications http://www.engineersedge.com/spring_torsion_calc.htm Delrin Specifications http://www.interstateplastics.com/meta/fmdelrin.htm Colorado Space Grant Consortium

Issues and Concerns Temperature effects on hinge operation and Delrin material Determine optimum spring constant value Coefficient of friction on hinge due to 6060 Aluminum and Delrin Reduce size and mass of components Vibration dampening Colorado Space Grant Consortium