CalSat Gerald Frolich – Project Manager / Electronics David Baroff – Systems Dickson Yuen – Manufacturing Seth Drake – Attitude Control / Electronics CalSat [1]

Mission Objectives To design and build a 1U(10x10x11cm) CalSat to calibrate/validate NASA’s CubeSat test environment. To work with JPL in the review of the CubeSat’s existing test requirements and to increase reliability on CubeSat mission success, in light of its Class D classification. [2]

Program Requirements (Level 1) The project will survey existing maximum predicted environments (MPE) and develop a MPE mission set for approved CubeSats. Establish a set of labs that can be used to teach spacecraft (i.e. CubeSat) design using CalSat and qualify the University CubeSat environmental testing equipment. [3]

Program Requirements (Level 1) CalSat will adhere to CubeSat.org “CubeSat Acceptance Checklist” regarding CubeSat physical properties as defined in revision 12 (August 1, 2009; Riki Munakata) [4]

Program Requirements (Level 1) CalSat will comply with the General Environmental Verification Standard (GEVS) requirements established by NASA as defined in LSP-REQ-317.01 Revision B (January 30, 2014; Amanda Mitskevich) [5]

Project Requirements (Level 2) The chassis will be constructed using aluminum 7075, 6061, 5005, and/or 5052 for both the main CalSat structure and the rails. [6]

Project Requirements (Level 2) Be able to measure and withstand random vibration of MPE plus 6 dB for 3 minutes, on all 3 axes. Be able to measure and withstand sinusoidal vibration of MPE plus 6 dB for content that is not covered by random vibration testing. Survive and record testing of shock of MPE plus 6 dB on all 3 axes. Demonstrate survivability for all types of radiation determined by the mission profile set. Will measure change in acceleration on 3 axes. Can withstand and measure temperatures in the minimum range of -14°C to 71°C or MPE +/- 10°C. Will measure and record pressure determined by MPE.

System Requirements (Level 3) Will use a vibration sensor to measure random/sinusoidal vibration on the CalSat. Will use an accelerometer to measure shock and acceleration on the CalSat. Radiation exposure levels on the CalSat will be measured using a dosimeter. Temperature will be measured with a temperature sensor. Change in pressure will be sensed using a vacuum sensor. Batteries must last a minimum of 3 hours to complete testing.

Block Diagram Dosimeter SD Card CubeSat Chassis (encompasses all elements) Force Sensor Motherboard Motherboard Vibration Sensor Development Board Vacuum Sensor Battery Pack / Thermal Sensor Accelerometer/ Shock Sensor *All sensors receive power from mother board and transmit data in return

CubeSat Kit Kit components: Structure Modular Chassis – Aluminum, solid wall, adheres to CubeSat standards Electronics: Motherboard, Development Board and Pluggable Processor Modules Wireless and Wired Communications CubeSat Kit Bus Flexible Power Module Compatibility Mass Storage Software CubeSat processor specific library for motherboard interface Pumpkin Salvo Pro Real-Time Operating System [7]

CubeSat Chassis Made with Aluminum Alloy 7075-T6 Modular, skeletonized or solid wall Space proven (over 30+) Mass: Skeletonized: 71 grams per wall Solid: 132 grams [8]

CubeSat Motherboard Single Board Computer for Harsh Environments PPM (pluggable processor module) I2C, USB 2.0, SD Card socket Mass: 77 grams , Suitable for temps: -40C to +85C Operating specs: 0.5 mA, 1.65V 104 I/O pin connectors Designed to install seamlessly into Pumpkin CubeSat chassis [9]

Battery Pack High Capacity Battery Pack designed for Nano-Satellites 8.4V, 5200mAh (or 16.8V, 2600mAh) 4 Li-Ion cells Built-in Thermal Sensor Stackable for increased capacity Dimensions: 94 x 88 x 23 mm Mass: 240 grams [10]

Dosimeter Highly Sensitive, Low Power Radiation Monitoring Measure Radiation Levels (total ionizing dose) - Range: up to 40kRads Manufacturer: Teledyne Microelectronics Dimensions: 1.4” x 1.0” x 0.040” Weight: 20 grams Power consumption: 10 mA @ min13-max40V [11]

Accelerometer / Shock Sensor Honeywell QA-3000 Accelerometer Inertial sensor developed for spacecraft navigation systems Analog output Input: +/- 60 G Accurate within .004 G Mass: 71 grams Dimensions : 2.56cm x 1.49 cm Stainless steel casing Environmentally rugged -28C to 78C operating temps Withstand shock up to 100G [12]

Vibration Sensor Columbia Research Labs 972 V5 Vibration/Temperature Transmitter Two Signal outputs, vibration level and temperature Accuracy: 0-50 G peak vibration +/- 1.5 degrees C Two casing designs H1, H2 Mass: H1 – 150 grams; H2 – 230 grams Dimensions: H1 – 3.81 cm x 3.8 cm x 2.67 cm H2 – 3.18 cm diameter x 6.35 cm Operates at 10V, 4 mA [13]

Force Sensor FSS-SMT Series FSS020wngx Force sensing range: 0-20 N Surface mountable Operates at -40 C to +85 C Shock tested to 150 G Stainless steel ball for force compression

Vacuum Sensor Stellar Tech IT30 Intelligent Pressure Transducer Operates at min. 8V, ~25mA Dimensions: 8.51 cm x 3.81cm Range: 0-30,000 PSI Accurate within 0.1% Stainless steel Designed for harsh environments: -40 C to +185 C Fast sampling (100Ks/s) [15]

Power / Mass Budget Item Mass (g) Current (mA) Voltage(V) Power (mW) CubeSat Kit/ MSP430, Skeletonized-Wall 1 U 436 N/A NA Motherboard (MB) 77 0.5 1.65 0.825 Delkin Industrial temperature range 2GB SD Card 9 Microcontroller 35 200 2.7 540 Nano Power Battery Pack 240 Dosimeter 20 10 13 130 Accelerometer / Shock Sensor 71 16 208 Vibration Sensor 150 4 40 Force Sensor  TBD 1.2 6 7.2 Pressure (Vaccuum) Sensor 255 25 8 Total 1283 256.70   1126.03 W/(15% Margin) 1475.45 295.21 1294.93

Chassis Material Trade Off Study Aluminum between 87.2-91.4% Zinc between 5.1-6.1% Magnesium between 2.1-2.9% Copper between 1.2-2.0% Density 2.8 g/cm3 Strength-to-weight ratio 211kN-m/kg Most expensive 6061-T6 Aluminum between 95.9-98.6% Magnesium between .8-1.2% Silicon between .4-.8% Iron between 0-.7% Density 2.7 g/cm3 Strength-to-weight ratio 115kN-m/kg 5005 Aluminum between 97.0-99.5% Magnesium between .5-1.1% Iron between 0-.7% Density 2.7 g/cm3 Strength-to-weight ratio 85kN-m/kg 5052 Aluminum between 95.8-97.7% Magnesium between 2.2-2.8% Iron between 0-.4% Density 2.68 g/cm3 Strength-to-weight ratio 116kN-m/kg [16]

Detailed Cost Item Cost Part Number Seller Comments CubeSat Kit/ MSP430, Skeletonized-Wall 1 U $7,500 711-00282 PumpkinSat Chasis and Programming Tools Pumpkin Salvo Pro (TI's MSP430)   709-00217 Included in Kit Pumpkin MSP430 CubeSat Kit Software 709-00332 HCC-Embedded MSP430 EFFS-THIN SD Card Library 709-00371 Pumpkin JFPC-MSP430 Programming Adapter 634-00334 TI MSP430 USB Flash Emulation Tool 633-00299 Pumpkin MSP-TS430PM64 Adapter 710-00509 Pumpkin Pluggable Processor Module A1 710-0485 Development Board (DB) $1,300 710-00297 Motherboard (MB) $1,200 710-00484 Delkin Industrial temperature range 2GB SD Card $180 634-00456 Range of -40C to +85C Microcontroller $17 MSP-EXP430FR5969 TI Nano Power Battery Pack $2,014 BP4 GOMSpace Includes Temperature Sensor External Power Supply 5Vdx, 4A $60 632-00298 Motherboard Supply External Power Supply 6-12Vdx 632-00413 Development Board Supply Dosimeter TBD UDOS001 Teledyne Measures up to 40k Rads Accelerometer / Shock Sensor QA3000 Honeywell (+/-) 60G and 100G Shock Vibration / Temperature Sensor 972-V5-H1 Columbia R.L. 0-50 G Force Sensor FSS-SMT 0-20 N Pressure (Vacuum) Sensor IT30XX Stellar Tech. 0-30,000 PSI Pelican Ruggedized Transport Case $200 632-00372 Not Included In Budget Personalized Training (per hour) $350 713-00373 DVC 1 Desktop Vacuum Chamber 1 natural aluminum base $8,995 711-00652 Total $12,331 After Tax $13,317 After Tax W/(600% Margin ) (estimate $2,000-$15,000 a sensor) $79,904.82

Prototype Model

Prototype Model

Prototype Model

Block Diagram

Power / Mass Budget (Model) Item Mass (g) Current (mA) Voltage(V) Power (mW) PLA Filament 65 N/A Arduino Mega 2560 R3 34.9 50 5 250 Data Logging Shield 22 14 70 SanDisk 8GB Memory Card 8.5 Li-Ion Battery 90.7   Geiger Counter 30 150 Vibration Sensor 0.6 0.022 0.11 Optical Dust Sensor 16 20 100 10 Degrees of Freedom IMU 2.8 5.115 25.575 Slow Vibration Sensor Switch 0.3 Fast Vibration Sensor Switch Total 271.10 159.14 795.69 W/(15% Margin) 311.77 183.01 915.04

Interface Definition

Battery Trade Off Study (Model) Lithium-Ion Nickel Cadmium Nickel-Metal-Hydride Pros Long shelf-life, in any state-of-charge Most dependable batteries Fast and simple charge Cons Lowest energy density of the three Environmentally unfriendly High self-discharge Pros High energy density Low self-discharge (Less then half that of NiCd and NiMH) Cons Requires battery protection circuit Moderate discharge current Subject to aging, even if not in use Pros Environmentally friendly 30-40% higher capacity in energy density then NiCd Cons Recommended to use with load currents between .2C - .5C High self-discharge (Can have lower self-discharge, but will lose energy density) Generates more heat and requires longer charge time compared to NiCd [17]

Detailed Cost (Model) Item Cost Cost Per Unit Quantity Part Number Seller PLA Filament None N/A Self Arduino Mega 2560 R3 $45.95 1 11061 Sparkfun Data Logging Shield $19.95 1141 Adafruit SanDisk 8GB Memory Card $5.95 Amazon Li-Ion Battery $13.99 Geiger Counter $149.95 11345 Vibration Sensor $2.95 9198 Optical Dust Sensor $11.95 9689 10 Degrees of Freedom IMU $59.90 $29.95 2 1604 Slow Vibration Sensor Switch (Hard to trigger) $1.90 $0.95 1767 Fast Vibration Sensor Switch (Easy to trigger) 1766 Total $314.39 After Tax $339.54 After Tax W/(25% Margin) $424.43

Schedule

Schedule

Schedule

Appendix: Sources http://www.nasa.gov/images/content/429961main_cubesat_1.jpg http://upload.wikimedia.org/wikipedia/commons/7/73/ F-1_CubeSat_thermal_vacuum_test.jpg http://wallpaperank.com/wp-content/uploads/2013/10/Outer-Space-NASA-Wallpaper.jpg http://dww.cubesat.org/images/developers/cac_rev12.pdf http://www.nasa.gov/pdf/627972main_LSP-REQ-317_01A.pdf http://www.cubesatkit.com/images/cubesatkit_1u-revd-skeleton.jpg http://www.cubesatkit.com/content/overview.html http://www.cubesatkit.com/docs/cubesatkitsystemchart.pdf http://www.cubesatkit.com/docs/datasheet/DS_CSK_MB_710-00484-D.pdf http://gomspace.com/index.php?p=products-bp4 http://www.teledynemicro.com/product/radiation-dosimeter https://aero1.honeywell.com/inertsensor/docs/qa3000.pdf http://www.crlsensors.com/datasheets/972-V5-H1.pdf http://sensing.honeywell.com/index.php/ci_id/44994/la_id/1/ http://www.stellartech.com/products/techsheets-press/it30XX.pdf http://www.makeitfrom.com http://batteryuniversity.com/learn/article/whats_the_best_battery