1. DINO Peer Review 13 November 2015 Mechanisms Shilling, Tim Martinez, Michael

2. DINO Peer Review 13 November 2015 Colorado Space Grant Consortium2 Introduction Mechanisms includes restraints and release for: –COMM Antennas –Aerofins –FITS thin film solar arrays The mechanisms will release the deployables in a predetermined order –Tip mass –Antennas –FITS –Aerofins The restraint mechanisms are based around Planetary Systems’ Lightband, Starsys’ HOP (High Output Paraffin Actuator) and TiNi Aerospace’s Frangibolt

3. DINO Peer Review 13 November 2015 Colorado Space Grant Consortium3 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

4. DINO Peer Review 13 November 2015 Colorado Space Grant Consortium4 Requirements Imposed on Others 6 Hi/Low lines to signal different stages of deployment –Aerofins Released: 2 –FITS Released: 2 –Boom Released: 1 –Antenna Released: 1 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 4 Frangibolts 25W @ 28V for 30 Sec –FITS and Aerofins 4 composite hinges requiring 10W @ 28V for 1 minute –Two per Aerofin –Two Aerofins 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 aerofin –Requires data lines for two thermal couple (Sampling once per second)

5. DINO Peer Review 13 November 2015 Colorado Space Grant Consortium5 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

6. DINO Peer Review 13 November 2015 Colorado Space Grant Consortium6 Thin Film Solar Array (FITS) Responsibility Microsat FITS Restraint Panel Deployment Hinges CSGC Restraint/release system hardware General Provided by Microsat Released with the in-house release system (IRS) Preloaded to 100lb Upon Release deployment is almost instantaneous

7. DINO Peer Review 13 November 2015 Colorado Space Grant Consortium7 Flow Chart - FITS Input and Control Frangibolt 1 25 watts @ 28V High/Low output (Switch signaling final released position) Frangibolt 2 25 watts @ 28V High/Low output (Switch signaling final released position)

8. DINO Peer Review 13 November 2015 Colorado Space Grant Consortium8 FITS System - Stowed Stowed Solar Array Envelope (0.318 x 0.184 x 0.033 m) Volume = 0.0019 m 3 / Wing (0.067 ft 3 ) / Wing Deployment Hinge Restraint Panel Separation Device

9. DINO Peer Review 13 November 2015 Colorado Space Grant Consortium9 Deployed driving requirements - Power - 13 Vdc and 60 Watts @EOL Deployed Solar Array 1.10 m 2 / Wing Fold Integrated Thin Film Stiffener (FITS) Stainless Steel CIGS Array 85 Watts BOL - AMO Deployed Solar Array Meets All Requirements 1.257 m 0.439 m 1.636 m FITS System - Deployed

10. DINO Peer Review 13 November 2015 Colorado Space Grant Consortium10 Frangibolt

11. DINO Peer Review 13 November 2015 Colorado Space Grant Consortium11 Specifications

12. DINO Peer Review 13 November 2015 Colorado Space Grant Consortium12 Aerofins General 2 Composite panels Solar Arrays mounted to Panels Deployed with 4 composite hinges from CTD Held down by Frangibolts Deployed separately Responsibility CTD Composite aerofins Composite Hinges (With Mounts) Ability to interface with Restraint/release system hardware CSGC Restraint/release system hardware

13. DINO Peer Review 13 November 2015 Colorado Space Grant Consortium13 Flow Chart - Aerofins Input and Control Aerofins Frangibolt 1 25 watts @ 28V Composite Hinges 10 watts @ 28V per Hinge for 1 minute 2-4 Hinges required High/Low output (Switch signaling final deployed position) High/Low output (Switch signaling final released position) and turns off Frangibolt

14. DINO Peer Review 13 November 2015 Colorado Space Grant Consortium14 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

15. DINO Peer Review 13 November 2015 Colorado Space Grant Consortium15 Aerofin Deployment / Stabilization Major Cone Major Cup Aerofin Minor Cone Minor Cup Side Panel Frangibolt Housing

16. DINO Peer Review 13 November 2015 Colorado Space Grant Consortium16 Iso~Grid Mounting Minimal reduction in Iso~Grid strength. Central Cup spreads load stress over wider area, reducing flex on Aero~Fin. “Four Point” minor cones provides horizontal & vertical stabilization.

17. DINO Peer Review 13 November 2015 Colorado Space Grant Consortium17 Cup Cones

18. DINO Peer Review 13 November 2015 Colorado Space Grant Consortium18 Central Cup & Actuator Housing Frangi~Bolt Actuator captive in housing. Two Disc Springs to absorb energy of Frangi~Bolt Release. All Materials 6061 AL

19. DINO Peer Review 13 November 2015 Colorado Space Grant Consortium19 Central Cone Two Piece Mount (6061 Al) w/ one Disk Spring to absorb energy of Frangi~Bolt Release Disk Spring transmits energy to rear plate, which spreads force over wider area, reducing shock to Aero~Fins. Cone material: Delrin 500

20. DINO Peer Review 13 November 2015 Colorado Space Grant Consortium20 Disk Spring Data Size & deflection are two Major advantages vs. conventional Spring. Three Spring Disk @ 0.240in vs. Two standard springs @ 2.000in

21. DINO Peer Review 13 November 2015 Colorado Space Grant Consortium21 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

22. DINO Peer Review 13 November 2015 Colorado Space Grant Consortium22 Testing Plan - Aerofins AerofinStructure SledAir table CTD Hinge Structure Air table Sled

23. DINO Peer Review 13 November 2015 Colorado Space Grant Consortium23 Testing Plan - Release System Fit test Composite hinges Structural Fangibolt Hanging Weight test Preloading Shock absorption Damage to Hinges? Environment Warm hinge release system deployment Aerofin Structure Sled Air table CTD Hinge Structure Air table

24. DINO Peer Review 13 November 2015 Colorado Space Grant Consortium24 Parts List In-House Testing equipment FITS Aerofins Release system Outsourced springs Aluminum parts Outsourced Aerofins: Free HOP: Free FITS: Free Arrays Hinges 3 Fringebolt: Free Actuator 6 bolts: $100 each Reset Tool: TBD Tip mass Lightband Tether

25. DINO Peer Review 13 November 2015 Colorado Space Grant Consortium25 Issues and Concerns (Things to be done) To get to CDR –Complete Prototyping How did the Release systems perform –Testing to insure functionality, at least in std atmospheric conditions –Antenna release design –Documentation –Fits release system, How does Microsat want to deal with the Frangibot?

26. DINO Peer Review 13 November 2015 Structures Shilling, Tim McArthur, Grayson Schumacher, Ted Ko, Paul Jones, Robert

27. DINO Peer Review 13 November 2015 Colorado Space Grant Consortium27 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.)

28. DINO Peer Review 13 November 2015 Colorado Space Grant Consortium28 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

29. DINO Peer Review 13 November 2015 Colorado Space Grant Consortium29 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 Components may not be greater then 2in deep without prior approval from Structures and Systems

30. DINO Peer Review 13 November 2015 Colorado Space Grant Consortium30 ICU Envelope

31. DINO Peer Review 13 November 2015 Colorado Space Grant Consortium31 Exploded View FITSAerofinsPower Panel COMM Cameras C&DH + ADCS Antenna Release

32. DINO Peer Review 13 November 2015 Colorado Space Grant Consortium32 Main Structure Mass: 3.52kg Height:12.25in Diameter: 17.32in Material: Al 6061 Similar design to Three Corner Satellite

33. DINO Peer Review 13 November 2015 Colorado Space Grant Consortium33 Nadir Plate Iso-Grid Design Mounting plate for Lightband systems

34. DINO Peer Review 13 November 2015 Colorado Space Grant Consortium34 Side Panels

35. DINO Peer Review 13 November 2015 Colorado Space Grant Consortium35 Finite Element Analysis Analyze the Isogrid structure to get an idea of its performance before building a test specimen. Examine the trade off between total mass and stiffness Requirements –Stiffness: Fundamental frequency > 100 Hz. –Withstand a 20 G force in each direction

36. DINO Peer Review 13 November 2015 Colorado Space Grant Consortium36 Model Details Global size = 3.0328 mm Tolerance = 0.15164 mm Touching faces bonded Material: Al 6061 linear elastic isotropic Jacobian 4pt check Restraints set as immovable (no translation) Restraints located at each of the 8 mounting wholes 20 G force acting through the center of gravity

37. DINO Peer Review 13 November 2015 Colorado Space Grant Consortium37 General Drawings Isogrid side Back of panel Isogrid with Outer Plate Isogrid

38. DINO Peer Review 13 November 2015 Colorado Space Grant Consortium38 Design Options Option 1 - 0.25 in. thick panel with no outer plate - mass = 0.339 kg - Stiffness = 278.16 Hz. Option 2 - 0.125 in. thick panel with no outer plate - mass = 0.170 kg - Stiffness = 147.59 Hz. Option 3 - 0.20 in. thick panel with 0.05 in. thick outer plate - mass = panel + outer plate = 0.272 + 0.223 = 0.495 kg - Stiffness = 295.71 Hz. Option 4 - 0.075 in. thick panel with 0.05 in thick outer plate - mass = panel + outer plate = 0.102 + 0.223 = 0.325 kg - Stiffness = 139.95 Hz.

39. DINO Peer Review 13 November 2015 Colorado Space Grant Consortium39 Chosen Design Option 1 - 0.25 in. thick panel with no outer plate - mass = 0.339 kg - Stiffness = 278.16 Hz. Offered the best trade off between mass and stiffness. Easy to manufacture because one does not have to worry about leaving an outer wall.

40. DINO Peer Review 13 November 2015 Colorado Space Grant Consortium40 Analysis Stress calculated for a 20 G force acting solely in one of the three axis Stress calculated in von Mises stress (N/m^2) Design check plot generated for FOS of 2 based on stress The stress plots also resemble the scaled deformed shape

41. DINO Peer Review 13 November 2015 Colorado Space Grant Consortium41 Plots for Y Direction Stress Design Check Red < FOS = 2 < Blue

42. DINO Peer Review 13 November 2015 Colorado Space Grant Consortium42 Plots for X Direction StressDesign Check Red < FOS = 2 < Blue

43. DINO Peer Review 13 November 2015 Colorado Space Grant Consortium43 Plots for Z Direction StressDesign Check Red < FOS = 2 < Blue

44. DINO Peer Review 13 November 2015 Colorado Space Grant Consortium44 Plot Interpretation All of the design check plots show the entire panel in blue, meaning that all areas equal or exceed a factor of safety equal to 2 These two types of plots prove the side panel will withstand the 20 G forces

45. DINO Peer Review 13 November 2015 Colorado Space Grant Consortium45 Issues and Concerns Meshing the structure as a whole, including all side panels, top and bottom plates. Several attempts have been made with multiple problems. How to simulate the boxes attached to the structure. –Point mass or Sheet mass

46. DINO Peer Review 13 November 2015 Colorado Space Grant Consortium46 Drawing Package

47. DINO Peer Review 13 November 2015 Colorado Space Grant Consortium47 ADCS + C&DH Box Design

48. DINO Peer Review 13 November 2015 Colorado Space Grant Consortium48 Camera Box Pieces Outer Box -Holds camera at ? deg angle -Allows access to USB port and power supply -Protects circuit board -- 1/8 in. thick walls Camera Bracket -Secures camera in box -Supports circuit board *** Revision A, Awaiting Final Camera Selection

49. DINO Peer Review 13 November 2015 Colorado Space Grant Consortium49 Complete Camera Box Full assembly of camera box Complete Assembly -Encloses camera -Mounts to earth facing plate -Holds camera at 30deg angle -Manufacturing done as a short component

50. DINO Peer Review 13 November 2015 Colorado Space Grant Consortium50 Comm Box Use already designed and tested box Mounting plate allows connection to Satellite isogrid. Constructed of Al6061 and anodized TNC?

51. DINO Peer Review 13 November 2015 Colorado Space Grant Consortium51 Environmental Analysis

52. DINO Peer Review 13 November 2015 Colorado Space Grant Consortium52 The Harsh Environment Protection Against: –Atomic Oxygen (AO) –High Energy Protons and Electrons –Debris and Micrometeors –Radiation The Toughest Opponent at ISS orbit

53. DINO Peer Review 13 November 2015 Colorado Space Grant Consortium53 Atomic Oxygen Increases with the angle of incidence with Earth Decays material in direct contact –The rate of decay is negligible –AO is only a design factor to account for when the mission duration is over a couple years

54. DINO Peer Review 13 November 2015 Colorado Space Grant Consortium54 High Energy Protons and Electrons Only affects the outer region of the satellite A thin layer of material stops the damage The inflicted amount of decay is negligible over the 6 month mission

55. DINO Peer Review 13 November 2015 Colorado Space Grant Consortium55 Debris and Micrometeors Material travels at high velocity The impacts are on the scale of a few centimeters These impacts would not infringe upon the satellites operation

56. DINO Peer Review 13 November 2015 Colorado Space Grant Consortium56 Radiation Factors Solar Activity Cycle Trapped Protons Galactic Cosmic Radiation Solar Flare Protons Solar Flare Heavy Ions Inner Zone Electrons

57. DINO Peer Review 13 November 2015 Colorado Space Grant Consortium57 Solar Activity Cycle The Sun has a 22 year cycle The cycle was at the 50 year Mauder Minimum in the year 2000 The mission will be launched in 2005 The Solar Cycle reaches a minimum in 2006 The Sunspot Cycle will be low

58. DINO Peer Review 13 November 2015 Colorado Space Grant Consortium58

59. DINO Peer Review 13 November 2015 Colorado Space Grant Consortium59 Unimportant Factors Solar Flare Protons Solar Flare Heavy Ions –Only occur during Solar Maximum

60. DINO Peer Review 13 November 2015 Colorado Space Grant Consortium60 ISS orbit Protection Inner Zone Electrons Trapped Protons –Not a design factor Altitude of mission is much lower than where these two factors cause damage

61. DINO Peer Review 13 November 2015 Colorado Space Grant Consortium61 Galactic Cosmic Radiation High velocities strip the atoms of their nucleus Varies with the solar cycle At a maximum during the Solar Minimum –At a maximum during the missions duration

62. DINO Peer Review 13 November 2015 Colorado Space Grant Consortium62

63. DINO Peer Review 13 November 2015 Colorado Space Grant Consortium63 Galactic Cosmic Radiation Not a factor due to the low ISS orbit of 4000km Mainly attacks DNA –Very harmful to manned missions

64. DINO Peer Review 13 November 2015 Colorado Space Grant Consortium64 Recommendations To stop radiation –Use the.25 in thick aluminum To guard against Micrometeors, AO, Debris, high and low temperatures and High Energy Protons and Electrons Use the MLI blanket

65. DINO Peer Review 13 November 2015 Colorado Space Grant Consortium65 Conclusion The damaging effects of the environment are suppressed with the MLI blanket The Radiation is suppressed by the aluminum wall The satellite will function properly

66. DINO Peer Review 13 November 2015 Colorado Space Grant Consortium66 Early Testing FEA –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.

67. DINO Peer Review 13 November 2015 Colorado Space Grant Consortium67 Testing Plans

68. DINO Peer Review 13 November 2015 Colorado Space Grant Consortium68 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

69. DINO Peer Review 13 November 2015 Colorado Space Grant Consortium69 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

70. DINO Peer Review 13 November 2015 Colorado Space Grant Consortium70 Budgeted ComponentQuantity Unit Price Total Price Side Panels15$18.57$278.55 Bulkheads4$130.00$520.00 Boxes30$80.00$2,400.00 Fastners2000$0.75$1,500.00 Anodizing1$500.00 Total: $5,198.55

71. DINO Peer Review 13 November 2015 Colorado Space Grant Consortium71 Issues and Concerns (Things to be done) To get to CDR –Complete FEA How is the composite top panel going to effect things? –Boxes Design –Need more concrete info, maybe I should have a 1 on 1 meeting with each team Position –Design decisions on placement to ensure box design corresponds –Documentation –What kind of testing should be done?

72. DINO Peer Review 13 November 2015 Mechanical Ground Support Equipment The support for assembly.

73. DINO Peer Review 13 November 2015 Colorado Space Grant Consortium73 Purpose Assist assembly of satellite. Allow easy integration of hardware, wiring, mechanisms, side panels. Allow easy transportation. Allow easy accessibility.

74. DINO Peer Review 13 November 2015 Colorado Space Grant Consortium74 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.

75. DINO Peer Review 13 November 2015 Colorado Space Grant Consortium75 Requirements Met: Axis enables 57 degree rotation in every direction. Satellite or base will each have at least five screw points and will stay attached during rotation. MGSE allows “flowering” of side panels.

76. DINO Peer Review 13 November 2015 Colorado Space Grant Consortium76 MGSE Measurements

77. DINO Peer Review 13 November 2015 Colorado Space Grant Consortium77

78. DINO Peer Review 13 November 2015 Colorado Space Grant Consortium78 Parts List & Pricing

79. DINO Peer Review 13 November 2015 Colorado Space Grant Consortium79 Issues and Concerns: Cost Stability