Structures March 13, 2004

Introduction 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

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

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, unless approved. Components may not be greater then 3in deep without prior approval from Structures and Systems Colorado Space Grant Consortium

ICU Envelope Colorado Space Grant Consortium

Main Structure Mass: 3.93kg Height:12.5in Diameter: 17.76in Material: Al 6061 Similar design to Three Corner Satellite Envelope may be exceeded if FITS is too Large. If this is the case, solutions are lined up. Colorado Space Grant Consortium

Main Structure Max Solar Array Size Colorado Space Grant Consortium

Nadir Plate Colorado Space Grant Consortium

Zenith Plate Colorado Space Grant Consortium

Side Panels Colorado Space Grant Consortium

FEA March 13, 2004

Structure Specification Material: Aluminum 6061 for all components. Specifications: The structures (first mode) Natural Frequency should be beyond 100 Hz . Colorado Space Grant Consortium

3-D Analysis for DINO side panel Software's: COSMOS Works 7.0 ANSYS 7.1 Analysis done in both software's. Technical Limitations faced. Colorado Space Grant Consortium

Plots for modal analysis for side panel Plots with COSMOS Works 7.0 The first mode was observed at 277Hz. Factor of safety of 2 for structure. Colorado Space Grant Consortium

Displacements plots for the Side Panel Displacement Plot using Solid mesh. The maximum displacement was observed to be 123 inches at the center portion of the panel at its first mode. Colorado Space Grant Consortium

Ansys Vs COSMOS Works The model for Ansys was checked for 2-D. The plots of side panel using Ansys. The first mode was observed at 106 Hz. Merely meeting requirements. Colorado Space Grant Consortium

Checking with COSMOS Works Shell mesh used for analysis check. The first mode was observed at 265 Hz. Also, proved to be giving a factor of safety of 2. Discussion. Colorado Space Grant Consortium

Displacements for Side Panel The displacements are for Side Panel with shell mesh. The maximum displacement was observed to be 125 inches. Colorado Space Grant Consortium

Analysis of Nadir Plate The nadir plate and the outer box were analyzed only in COSMOS Works. The first mode occurred at 554 Hz. A factor of more than 5. Colorado Space Grant Consortium

Displacements Plots for Nadir Plate The displacement plot for the assembly was for the first mode with solid mesh. The maximum displacement was seen to be 276 inches at the first mode. Colorado Space Grant Consortium

Vision The structure should do well as a whole since the modes occur at higher frequencies due to cumulative mass of the system. Further analysis of the structure needs to be done, optimization shall be the next step once we are done with the requirements of the structure. Analysis will be done with COSMOS Works and Ansys even though ,the latter is available as Educational License. Colorado Space Grant Consortium

Boxes March 13, 2004

Introduction Subsystem box designs include Safety Accessibility Boxes are designed to protect and secure components Accessibility There is enough space in each box for circuit boards and wires Holes will be added as needed All sockets are accessible Colorado Space Grant Consortium

Changes since PDR The C&DH and ADCS boxes were made into two separate boxes due to a dimension change. The Camera box dimensions were increased. Colorado Space Grant Consortium

Design Overview ADCS C&DH Science Comm Power Magnetometer PCB C&DH Science Camera Comm Radio & TNC Power 28V battery Boxes attached to isogrid side panel Magnetometer PCB C&DH TNC 28V Battery Boxes attached to isogrid bottom panel COMM-radio Camera Colorado Space Grant Consortium

ADCS 4.4 x 4.4 x 1.75 in. The x and y dimensions are 1 inch larger for isogrid attachment. The Connector can be placed on any side of the box. Colorado Space Grant Consortium

ADCS Magnetometer PCB 2.5 x 2.5 x .75 in. The location of the socket is accessible Colorado Space Grant Consortium

C&DH 4.5 x 4.5 x 5 in. Houses the Arcom Viper Flight Computer and Interface Boards Colorado Space Grant Consortium

Camera Box 8.64 x 6.75 x 4 in 7.5 degrees angles pointing down opposite direction Double mounting panel to secure the lenses Colorado Space Grant Consortium

COMM Radio Box 6.25 x 5.4 x 1.5 in. 1 additional RS-232 serial port to initialize radios Colorado Space Grant Consortium

COMM TNC Box Dimensions 6.1 x 7.3 x 1.3 in. 1 RS-232 serial port Colorado Space Grant Consortium

28V Battery 2.4 x 4.3 x 2.15 in. Designed for a tight fit on the x-axis at 2.4 in. 0.1 in. thickness 0.5 in. space 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 Colorado Space Grant Consortium

Conclusions Box Holes Camera Box Securing camera lenses Battery leak These will need to be added when the different subsystems are positive of their location and size Camera Box The camera box dimensions will be adjusted Securing camera lenses Dimensions might need to be changed to prevent cracks in the lenses Battery leak The cover should be designed to with hold this occurrence Small changes in the box dimensions will occur Colorado Space Grant Consortium

Testing and Budget March 13, 2004

Early Testing FEA Envelope Verification Mass Properties 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

Testing Plans Colorado Space Grant Consortium

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

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

Budgeted Side Panels 15 $18.57 $278.55 Bulkheads 4 $130.00 $520.00 Component Quantity Unit Price Total 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 Total:   $5,198.55 Colorado Space Grant Consortium

Issues and Concerns Complete FEA Boxes Documentation How is the composite top panel going to effect things? Boxes Design Connector info Lids built into isogrid? Documentation Colorado Space Grant Consortium

Mechanical Ground Support Equipment

Overall View Colorado Space Grant Consortium

Purpose Assist assembly of satellite. Allow easy integration of hardware, wiring, mechanisms, side panels. Allow easy transportation. Allow easy accessibility. Colorado Space Grant Consortium

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

PDR MGSE Colorado Space Grant Consortium

Changes Since PDR Added in a safety bar for the long arm. Implemented many “plates” to add to the strength and to lessen the need for drilling. Also, implemented a large plate, for simplicity, between the bottom plate and the “base” and between the satellite and the “cart.” Added several attachment points for the top and the bottom plates. Increased simplicity for the “base.” Decreased budget by the additions made. Colorado Space Grant Consortium

Requirements Met Width of the satellite is 27.5”. Flowering pattern present in MGSE. MGSE allows up to, and no more than, 54 degrees of rotation. Each side panel has 4 attachment points. The top panel has 8 attachment points. The bottom panel has 22 attachment points. (The satellite while assembled will have 22 attachment points. Colorado Space Grant Consortium

MGSE Schematics and Drawings Colorado Space Grant Consortium

Schematics and Drawings Colorado Space Grant Consortium

Schematics and Drawings Colorado Space Grant Consortium

Schematics and Drawings Colorado Space Grant Consortium

Rotation View Colorado Space Grant Consortium

Rotation View Colorado Space Grant Consortium

Parts and Price List: Colorado Space Grant Consortium