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

2. 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]

3. 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]

4. 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]

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

6. 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]

7. 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.

8. 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.

9. 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

10. 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]

11. 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]

12. 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]

13. 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]

14. 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 min13-max40V
[11]

15. 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]

16. 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]

17. 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

18. 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]

19. 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
W/(15% Margin)
295.21

20. Chassis Material Trade Off Study
Aluminum between %
Zinc between %
Magnesium between %
Copper between %
Density 2.8 g/cm3
Strength-to-weight ratio 211kN-m/kg
Most expensive
6061-T6
Aluminum between %
Magnesium between %
Silicon between .4-.8%
Iron between 0-.7%
Density 2.7 g/cm3
Strength-to-weight ratio 115kN-m/kg
5005
Aluminum between %
Magnesium between %
Iron between 0-.7%
Density 2.7 g/cm3
Strength-to-weight ratio 85kN-m/kg
5052
Aluminum between %
Magnesium between %
Iron between 0-.4%
Density 2.68 g/cm3
Strength-to-weight ratio 116kN-m/kg
[16]

21. Detailed Cost Item Cost Part Number Seller Comments
CubeSat Kit/ MSP430, Skeletonized-Wall 1 U
$7,500
PumpkinSat
Chasis and Programming Tools
Pumpkin Salvo Pro (TI's MSP430)
Included in Kit
Pumpkin MSP430 CubeSat Kit Software
HCC-Embedded MSP430 EFFS-THIN SD Card Library
Pumpkin JFPC-MSP430 Programming Adapter
TI MSP430 USB Flash Emulation Tool
Pumpkin MSP-TS430PM64 Adapter
Pumpkin Pluggable Processor Module A1
Development Board (DB)
$1,300
Motherboard (MB)
$1,200
Delkin Industrial temperature range 2GB SD Card
$180
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
Motherboard Supply
External Power Supply 6-12Vdx
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
Not Included In Budget
Personalized Training (per hour)
$350
DVC 1 Desktop Vacuum Chamber 1 natural aluminum base
$8,995
Total
$12,331
After Tax
$13,317
After Tax W/(600% Margin ) (estimate $2,000-$15,000 a sensor)
$79,904.82

22. Prototype Model

23. Prototype Model

24. Prototype Model

25. Block Diagram

26. 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

27. Interface Definition

28. 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]

29. 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

30. Schedule

31. Schedule

32. Schedule

33. Appendix: Sources
F-1_CubeSat_thermal_vacuum_test.jpg