DINO Peer Review 9252020 Mechanisms Shilling Tim Martinez

DINO Peer Review 9/25/2020 Mechanisms Shilling, Tim Martinez, Michael

DINO Peer Review 9/25/2020 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 Ti. Ni Aerospace’s Frangibolt Colorado Space Grant Consortium 2

DINO Peer Review 9/25/2020 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 Colorado Space Grant Consortium 3

DINO Peer Review 9/25/2020 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 18 W at 28 V for 1. 5 -2 minutes – Antenna Release • Lightband separator requiring 10 W @ 12 V for 1 minute (May Change) – Tip Mass Release • 4 Frangibolts 25 W @ 28 V for 30 Sec – FITS and Aerofins • 4 composite hinges requiring 10 W @ 28 V 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) Colorado Space Grant Consortium 4

DINO Peer Review 9/25/2020 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 Colorado Space Grant Consortium 5

DINO Peer Review 9/25/2020 Thin Film Solar Array (FITS) Responsibility General • Provided by Microsat • Released with the in-house release system (IRS) • FITS • Preloaded to 100 lb • Deployment Hinges • Restraint Panel • Upon Release deployment is CSGC almost instantaneous • Restraint/release system hardware Colorado Space Grant Consortium 6

DINO Peer Review 9/25/2020 Flow Chart - FITS Input and Control Frangibolt 1 25 watts @ 28 V High/Low output (Switch signaling final released position) Frangibolt 2 25 watts @ 28 V High/Low output (Switch signaling final released position) Colorado Space Grant Consortium 7

DINO Peer Review 9/25/2020 FITS System - 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 Separation Device Restraint Panel Colorado Space Grant Consortium 8

DINO Peer Review 9/25/2020 FITS System - Deployed 0. 439 m m 1. 257 m 1. 636 m 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 Colorado Space Grant Consortium 9

DINO Peer Review 9/25/2020 Frangibolt Colorado Space Grant Consortium 10

DINO Peer Review 9/25/2020 Specifications Colorado Space Grant Consortium 11

DINO Peer Review 9/25/2020 Aerofins General Responsibility • 2 Composite panels CTD • Solar Arrays mounted to Panels • Composite aerofins • Deployed with 4 composite hinges from CTD • Composite Hinges • Held down by Frangibolts • Deployed separately (With Mounts) • Ability to interface with Restraint/release system hardware CSGC • Restraint/release system hardware Colorado Space Grant Consortium 12

DINO Peer Review 9/25/2020 Flow Chart - Aerofins Input and Control Aerofins Frangibolt 1 25 watts @ 28 V Composite Hinges 10 watts @ 28 V per Hinge for 1 minute 2 -4 Hinges required High/Low output (Switch signaling final released position) and turns off Frangibolt High/Low output (Switch signaling final deployed position) Colorado Space Grant Consortium 13

DINO Peer Review 9/25/2020 Composite Hinges • • Provided by Composite Technology Development (CTD) Rigid in cooled State When Heated returns to Original Shape 4 composite hinges requiring 10 W @ 28 V for 1 minute Colorado Space Grant Consortium 14

DINO Peer Review 9/25/2020 Aerofin Deployment / Stabilization Aerofin Side Panel Minor Cup Minor Cone Frangibolt Housing Major Cone Major Cup Colorado Space Grant Consortium 15

DINO Peer Review 9/25/2020 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. Colorado Space Grant Consortium 16

DINO Peer Review 9/25/2020 Cup Cones Colorado Space Grant Consortium 17

DINO Peer Review 9/25/2020 Central Cup & Actuator Housing • Frangi~Bolt Actuator captive in housing. • Two Disc Springs to absorb energy of Frangi~Bolt Release. • All Materials 6061 AL Colorado Space Grant Consortium 18

DINO Peer Review 9/25/2020 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 Colorado Space Grant Consortium 19

DINO Peer Review 9/25/2020 Disk Spring Data Size & deflection are two Major advantages vs. conventional Spring. Three Spring Disk @ 0. 240 in vs. Two standard springs @ 2. 000 in Colorado Space Grant Consortium 20

DINO Peer Review 9/25/2020 Antenna Release System - HOP • • Pin Puller Less then 120 g 50 lbs of force One HOP releases Antennas • Total travel of HOP release Pin: . 3 in • Activated with 28 V at 18 watts for 2 minutes, which heats up the wax inside the piston, expanding it and causing the pin puller to move Colorado Space Grant Consortium 21

DINO Peer Review 9/25/2020 Testing Plan - Aerofins Aerofin CTD Hinge Structure Air table Sled Air table Colorado Space Grant Consortium 22

DINO Peer Review 9/25/2020 Testing Plan - Release System Aerofin • Fit test CTD Hinge Structure • Composite hinges • Structural • Fangibolt • Hanging Weight test • Preloading Air table Sled • Shock absorption • Damage to Hinges? Structure Air table • Environment • Warm hinge release system deployment Colorado Space Grant Consortium 23

DINO Peer Review 9/25/2020 Parts List In-House • Testing equipment Outsourced • Aerofins: Free • FITS • HOP: Free • Aerofins • FITS: Free • Release system • Outsourced springs • Aluminum parts • Arrays • Hinges • 3 Fringebolt: Free • Actuator • 6 bolts: $100 each • Reset Tool: TBD • Tip mass • Lightband • Tether Colorado Space Grant Consortium 24

DINO Peer Review 9/25/2020 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? Colorado Space Grant Consortium 25

DINO Peer Review 9/25/2020 Structures Shilling, Tim Mc. Arthur, Grayson Schumacher, Ted Ko, Paul Jones, Robert

DINO Peer Review 9/25/2020 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 27

DINO Peer Review 9/25/2020 Requirements Imposed on Structures • • • Entire Structure with mechanisms will be less then 9. 19 Kg Fixed base Natural Frequency > 100 Hz at the Shuttle interface plane (SIP). Center of mass is to be no more then. 25 in from centerline and 12 in 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 28

DINO Peer Review 9/25/2020 Requirements Imposed on Others • All systems will meet allocated size and mass budgets • No component may have a width > 8. 5 in or a height > 11 in • Components may not be greater then 2 in deep without prior approval from Structures and Systems Colorado Space Grant Consortium 29

DINO Peer Review 9/25/2020 ICU Envelope Colorado Space Grant Consortium 30

DINO Peer Review 9/25/2020 Exploded View FITS Aerofins Power Panel COMM Cameras Antenna Release C&DH + ADCS Colorado Space Grant Consortium 31

DINO Peer Review 9/25/2020 Main Structure • • • Mass: 3. 52 kg Height: 12. 25 in Diameter: 17. 32 in Material: Al 6061 Similar design to Three Corner Satellite Colorado Space Grant Consortium 32

DINO Peer Review 9/25/2020 Nadir Plate • Iso-Grid Design • Mounting plate for Lightband systems Colorado Space Grant Consortium 33

DINO Peer Review 9/25/2020 Side Panels Colorado Space Grant Consortium 34

DINO Peer Review 9/25/2020 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 Colorado Space Grant Consortium 35

DINO Peer Review 9/25/2020 Model Details • • Global size = 3. 0328 mm Tolerance = 0. 15164 mm Touching faces bonded Material: Al 6061 linear elastic isotropic Jacobian 4 pt 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 Colorado Space Grant Consortium 36

DINO Peer Review 9/25/2020 General Drawings Isogrid with Outer Plate Isogrid side Back of panel Colorado Space Grant Consortium 37

DINO Peer Review 9/25/2020 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. Colorado Space Grant Consortium 38

DINO Peer Review 9/25/2020 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. Colorado Space Grant Consortium 39

DINO Peer Review 9/25/2020 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 Colorado Space Grant Consortium 40

DINO Peer Review 9/25/2020 Plots for Y Direction Stress Design Check Red < FOS = 2 < Blue Colorado Space Grant Consortium 41

DINO Peer Review 9/25/2020 Plots for X Direction Stress Design Check Red < FOS = 2 < Blue Colorado Space Grant Consortium 42

DINO Peer Review 9/25/2020 Plots for Z Direction Stress Design Check Red < FOS = 2 < Blue Colorado Space Grant Consortium 43

DINO Peer Review 9/25/2020 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 Colorado Space Grant Consortium 44

DINO Peer Review 9/25/2020 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 Colorado Space Grant Consortium 45

DINO Peer Review 9/25/2020 Drawing Package Colorado Space Grant Consortium 46

DINO Peer Review 9/25/2020 ADCS + C&DH Box Design Colorado Space Grant Consortium 47

DINO Peer Review 9/25/2020 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 Colorado Space Grant Consortium 48

DINO Peer Review 9/25/2020 Complete Camera Box Complete Assembly -Encloses camera -Mounts to earth facing plate -Holds camera at 30 deg angle -Manufacturing done as a short component Full assembly of camera box Colorado Space Grant Consortium 49

DINO Peer Review 9/25/2020 Comm Box • Use already designed and tested box • Mounting plate allows connection to Satellite isogrid. • Constructed of Al 6061 and anodized • TNC? Colorado Space Grant Consortium 50

DINO Peer Review 9/25/2020 Environmental Analysis Colorado Space Grant Consortium 51

DINO Peer Review 9/25/2020 The Harsh Environment • Protection Against: – Atomic Oxygen (AO) – High Energy Protons and Electrons – Debris and Micrometeors – Radiation • The Toughest Opponent at ISS orbit Colorado Space Grant Consortium 52

DINO Peer Review 9/25/2020 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 Colorado Space Grant Consortium 53

DINO Peer Review 9/25/2020 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 Colorado Space Grant Consortium 54

DINO Peer Review 9/25/2020 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 Colorado Space Grant Consortium 55

DINO Peer Review 9/25/2020 Radiation Factors • Solar Activity Cycle • Trapped Protons • Galactic Cosmic Radiation • Solar Flare Protons • Solar Flare Heavy Ions • Inner Zone Electrons Colorado Space Grant Consortium 56

DINO Peer Review 9/25/2020 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 Colorado Space Grant Consortium 57

DINO Peer Review 9/25/2020 Colorado Space Grant Consortium 58

DINO Peer Review 9/25/2020 Unimportant Factors • Solar Flare Protons • Solar Flare Heavy Ions – Only occur during Solar Maximum Colorado Space Grant Consortium 59

DINO Peer Review 9/25/2020 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 Colorado Space Grant Consortium 60

DINO Peer Review 9/25/2020 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 Colorado Space Grant Consortium 61

DINO Peer Review 9/25/2020 Colorado Space Grant Consortium 62

DINO Peer Review 9/25/2020 Galactic Cosmic Radiation • Not a factor due to the low ISS orbit of 4000 km • Mainly attacks DNA – Very harmful to manned missions Colorado Space Grant Consortium 63

DINO Peer Review 9/25/2020 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 Colorado Space Grant Consortium 64

DINO Peer Review 9/25/2020 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 Colorado Space Grant Consortium 65

DINO Peer Review 9/25/2020 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. Colorado Space Grant Consortium 66

DINO Peer Review 9/25/2020 Testing Plans Colorado Space Grant Consortium 67

DINO Peer Review 9/25/2020 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 68

DINO Peer Review 9/25/2020 Parts List • • • Outsourced Estimated Fasteners: 2000 @ $. 75 = $1500 Anodizing: $500 6 Side panels. 9 x 12. 5 x. 25 in Al 6061 plates: $67 NIST 1 Nadir Plates. 17. 5 x 17 x. 75 in Al 6061 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 69

DINO Peer Review 9/25/2020 Budgeted Component Quantity Side Panels 15 Bulkheads 4 Boxes 30 Fastners $18. 57 $278. 55 $130. 00 $520. 00 $0. 75 $1, 500. 00 1 Total Price $80. 00 $2, 400. 00 2000 Anodizing Total: Unit Price $500. 00 Colorado Space Grant Consortium $500. 00 $5, 198. 55 70

DINO Peer Review 9/25/2020 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? Colorado Space Grant Consortium 71

DINO Peer Review 9/25/2020 Mechanical Ground Support Equipment The support for assembly.

DINO Peer Review 9/25/2020 Purpose • Assist assembly of satellite. • Allow easy integration of hardware, wiring, mechanisms, side panels. • Allow easy transportation. • Allow easy accessibility. Colorado Space Grant Consortium 73

DINO Peer Review 9/25/2020 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 74

DINO Peer Review 9/25/2020 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. Colorado Space Grant Consortium 75

DINO Peer Review 9/25/2020 MGSE Measurements Colorado Space Grant Consortium 76

DINO Peer Review 9/25/2020 Colorado Space Grant Consortium 77

DINO Peer Review 9/25/2020 Parts List & Pricing Colorado Space Grant Consortium 78

DINO Peer Review 9/25/2020 Issues and Concerns: • Cost • Stability Colorado Space Grant Consortium 79