1. Mechanisms
DINO CDR
March 13, 2004

2. 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
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3. 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
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4. 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 minutes
Antenna Release
Lightband separator requiring 12V for 1 minute (May Change)
Tip Mass Release
2 Frangibolts 28V for 30 Sec
FITS and CTD Panel
2 composite hinges requiring 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)
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5. Magic Semi-Rigid Boom
March 13, 2004

6. 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
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7. 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
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8. 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.
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9. Deployment System (As Configured for KC-135 Testing)
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10. 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.
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11. 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.
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12. 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
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13. 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.
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14. Changes since PDR
This configuration developed to replace the flexible tether discussed at PDR
Provides a more stable platform for the Tip Mass
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15. 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
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16. 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
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17. 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
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18. 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
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19. FITS
March 13, 2004

20. 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
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21. (Switch signaling final
Flow Chart - FITS
Input and Control
Frangibolt 1
25 28V
High/Low output
(Switch signaling final
released position)
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22. 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
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23. Solar Array Subsystem Overview
Stowed Solar Array Envelope
(0.381 x 0.19 x m)
Volume = m3 / Wing
Deployment Hinges
Frangibolt
Sep device
Restraint Panel
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24. Solar Array Subsystem Overview
Deployed driving requirements - Power - 19 Vdc and 90
Deployed Solar Array
1.14 m2 Fold Integrated Thin Film Stiffener (FITS) Stainless Steel CIGS Array
Deployed Solar Array Meets All Requirements
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25. Frangibolt
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26. Specifications
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27. Grayson McArthur Amanda Heaton March 13, 2004
CTD Deployable Panel
Grayson McArthur
Amanda Heaton
March 13, 2004

28. 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.
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29. Design Changes One panel Two double bladed hinges One frangibolt
Deploying parallel to velocity vector
Gathering numerical data for CTD
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30. Flow Chart - CTD Panel Input and Control Aerofins High/Low output
Frangibolt 1
25 28V
High/Low output
(Switch signaling final
released position) and
turns off Frangibolt
Composite Hinges
10 28V per
Hinge for 1 minute
2-4 Hinges required
High/Low output
(Switch signaling final
deployed position)
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31. 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
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32. Full Assembly Colorado Space Grant Consortium Magnetometer
Accelerometers
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33. Mechanical Drawings Modified Side panel Colorado Space Grant
Removed strut
Removed strut
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34. Mechanical Drawings Hinge Attachment Bracket Colorado Space Grant
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35. Mechanical Drawings
Bottom Cup
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36. Mechanical Drawing
Left Cup
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37. Mechanical Drawing
Right Cup
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38. Mechanical Drawings
Cone
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39. Frangibolt Release Execution Memory Composite 500 lbs holding force
28V
21 seconds
Increased temperature from power activates release.
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40. Composite Hinges Provided by Composite Technology Development (CTD)
Rigid in cooled State
When Heated returns to Original Shape
4 composite hinges requiring 28V for 1 minute
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41. Mass Table Component (how many) Mass Attachment plate (1) 0.0784 kg
Isogrid (1) kg
Cone (3) kg
Bracket (2) kg
Straight Cup (1) kg
Frangibolt (1)
0.020 kg
EMC Hinge (2) kg
Left/Right Cup (1 of each) kg
Assembly kg
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42. 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
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43. 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
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44. 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
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45. 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
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46. Issues and Concerns Attachment of frangibolt to structure
Running short on time
Component height
Task left to do
- Release system finalization
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47. Antenna Deployment Mechanism
March 13, 2004

48. 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
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49. 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.
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50. 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
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51. Function Description – Before Deployment
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52. Function Description - Deployed
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53. 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
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54. 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
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55. Functional Requirements and Compliance of Design
Mass requirements
Antenna system including cylinder must be less than 1 lb for a spring constant of 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
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56. Delrin Specifications
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57. Major Components of Subsystem
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58. Major Components - Base
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59. Major Components – Crossbeam
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60. Major Component – Hinge Cylinder
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61. Major Component – HOP Mount
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62. 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.
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63. 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
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64. Fabrication and Assembly
Machining Process will begin immediately upon approval
Operation testing --- undecided
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65. 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
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66. Documentation Torsion Spring Calculation Delrin Specifications
Delrin Specifications
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67. 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
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