1. RAFT Radar Fence Transponder Critical Design Review Bob Bruninga, CDR USN (ret) MIDN 1/C Ben Orloff MIDN 1/C Eric Kinzbrunner MIDN 1/C JoEllen Rose Midn 1/C Steven Schwarzer

2. RAFT Critical Design Review 223 Feb 2005  Assumption: Launch NET February 2006 RAFT Kickoff Apr 04 RAFT Kickoff Apr 04 RAFT USNA SRR Sep 04 RAFT USNA SRR Sep 04 RAFT PDR19 Nov 04 RAFT PDR19 Nov 04 RAFT Phase 0/1 Safety16 Dec 04 RAFT Phase 0/1 Safety16 Dec 04 RAFT Phase 2 Safety10 Feb 05 RAFT Phase 2 Safety10 Feb 05  RAFT CDR23 Feb 05  RAFT Flight Unit Testing May 05  RAFT Phase 3 Safety Aug 05  RAFT Delivery/Install Oct 05  RAFT Flight (STS-116) 09 Feb 06 Key Milestones: Schedule

3. RAFT Critical Design Review 323 Feb 2005 So Many CUBEsats 30 to 50 in Construction AIAA/USU Small Sat Conference 30% of papers were for PICO, NANO and CUBEsats All smaller than 10 cm How to Track them???

4. RAFT Critical Design Review 423 Feb 2005 Mission Statement  To provide the Navy Space Surveillance (NSSS) radar fence with a means to determine the bounds of a constellation of PicoSats otherwise undetectable by the radar fence  To enable NSSS to independently calibrate their transmit and receive beams using signals from RAFT.  This must be accomplished with two PicoSats, one that will actively transmit and receive, and one with a passively augmented radar cross-section.  Additionally, RAFT will provide experimental communications transponders for the Navy Military Affiliate Radio System, the United States Naval Academy’s Yard Patrol crafts, and the Amateur Satellite Service.

5. RAFT Critical Design Review 523 Feb 2005 NSSS Radar Fence

6. RAFT Critical Design Review 623 Feb 2005 RAFT1 Mission Architecture

7. RAFT Critical Design Review 723 Feb 2005 MARScom Mission Architecture

8. RAFT Critical Design Review 823 Feb 2005 Military Affiliate Radio System The Mission of the MARS system is to:  Provide auxiliary communications for military, federal and local disaster management officials  Assist in effecting communications under emergency conditions.  Handle morale and quasi-official communications traffic for members of the Armed Forces and authorized U.S. Government civilian personnel  Provide routine operations in support of MARSGRAMS and … contacts between service personnel and their families back home home.

9. RAFT Critical Design Review 923 Feb 2005 Yard Patrol Craft Application Unique UHF AM Uplink and HF SSB downlink

10. RAFT Critical Design Review 1023 Feb 2005 RAFT1 and MARScom 5” Cubes 3 Antennas Each Identical Mechanical

11. RAFT Critical Design Review 1123 Feb 2005

12. RAFT Critical Design Review 1223 Feb 2005 Pass Geometry

13. RAFT Critical Design Review 1323 Feb 2005 Raft1 Block Diagram

14. RAFT Critical Design Review 1423 Feb 2005 MARScom Block Diagram

15. RAFT Critical Design Review 1523 Feb 2005 RAFT Lifetime Estimate 6.5 Months 3.8 Mo

16. RAFT Critical Design Review 1623 Feb 2005 MARScom Lifetime Estimate 4.9 Months 3 Mo

17. RAFT Critical Design Review 1723 Feb 2005 RAFT Deployment Velocity of pair: 1.5 m/s Velocity of RAFT: 1.19 m/s Velocity of MARScom: 1.91 m/s

18. RAFT Critical Design Review 1823 Feb 2005 Low Friction Track Separation Test

19. RAFT Critical Design Review 1923 Feb 2005 Mechanical Design

20. RAFT Critical Design Review 2023 Feb 2005 Using “IDEAS” CAD Modeling

21. RAFT Critical Design Review 2123 Feb 2005 Assembly & Fasteners

22. RAFT Critical Design Review 2223 Feb 2005 Solar Panel Design on 5 Sides COTS Silicon Cells on PCB panel Covered with Clear Teflon Coating 1.5 Watt panel Mechanically rugged for rain/hail/birds PCsat Flight Heritage

23. RAFT Critical Design Review 2323 Feb 2005 Multi-Function Top Panel VHF Antenna holes HF whip hole Pockets for other satellite antennas and Sep Switch

24. RAFT Critical Design Review 2423 Feb 2005 RAFT1 Internal Diagram Top View Ant pocket & Sep SW

25. RAFT Critical Design Review 2523 Feb 2005 RAFT Internal Corner Detail Whip antenna and sep springs

26. RAFT Critical Design Review 2623 Feb 2005 RAFT SEP-Switch Corner Detail

27. RAFT Critical Design Review 2723 Feb 2005 MARS- comm Internal Top View

28. RAFT Critical Design Review 2823 Feb 2005 Side Panel

29. RAFT Critical Design Review 2923 Feb 2005 Side Panel Detail Loaded Side.25” thick

30. RAFT Critical Design Review 3023 Feb 2005 1. NEA DEVICE ACTUATES 2. LATCH ROD SLIDES FORWARD 3. DOOR SWINGS OPEN AND LATCHES 4. PICOSATs EJECT 1 2 3 4 Door in open, latched, landing position SSPL4410 LAUNCHER: Operation NOTE: Top Cover and Latchtrain Cover not shown in this view No separation until after both picosats clear launcher

31. RAFT Critical Design Review 3123 Feb 2005 For SSPL4410 with MEPSI: PICOSAT mass m = 1.6 kg = 3.5 lbs Preload > { 24 g x 3.5 lbs = 84 lbs } F = 125 lb max preload + 24 g x 3.5 lb  210 lbs 24 g calculated in SVP For SSPL5510 with RAFT: PICOSAT mass m = 7 kg = 15.4 lbs Preload > { 24 g x 15.4 lbs = 370 lbs } F = 500 lb max preload + 24 g x 15.4 lb  870 lbs SSPL4410 LAUNCHER: Preload and Launch Loads credit:

32. RAFT Critical Design Review 3223 Feb 2005 Side Panel Buckling Analysis

33. RAFT Critical Design Review 3323 Feb 2005 Structure Displacements

34. RAFT Critical Design Review 3423 Feb 2005 Depressurization Rate.040 hole Gives 2:1 margin for depressurization

35. RAFT Critical Design Review 3523 Feb 2005 Battery Box

36. RAFT Critical Design Review 3623 Feb 2005 Custom Side Panel for Antenna Crank and GSE Connector

37. RAFT Critical Design Review 3723 Feb 2005 RAFT Antenna Separation Mechanisms

38. RAFT Critical Design Review 3823 Feb 2005 Assembly Plan

39. RAFT Critical Design Review 3923 Feb 2005 RAFT Antenna Springs

40. RAFT Critical Design Review 4023 Feb 2005 Antenna Detail

41. RAFT Critical Design Review 4123 Feb 2005 Separation Velocities Click here for entire documentation

42. RAFT Critical Design Review 4223 Feb 2005 Antenna Buckling Analysis

43. RAFT Critical Design Review 4323 Feb 2005 Long-Wire Antenna Assy

44. RAFT Critical Design Review 4423 Feb 2005 Long-Wire Antenna Detail

45. RAFT Critical Design Review 4523 Feb 2005 VHF EZNEC Plots

46. RAFT Critical Design Review 4623 Feb 2005 RAFT1 Magnetic Attitude Control

47. RAFT Critical Design Review 4723 Feb 2005 Engineering Drawings  Top Panel Top Panel Top Panel  Bottom Panel Bottom Panel Bottom Panel  TX Panel (Page 1 / Page2) Page 1Page2Page 1Page2  RX Panel (Page 1 / Page 2) Page 1Page 2Page 1Page 2  HF Spool/Casing SpoolCasingSpoolCasing

48. RAFT Critical Design Review 4823 Feb 2005 Mass Budget (kg)

49. RAFT Critical Design Review 4923 Feb 2005 Each panel one pigtail All plug into Interface Board on the PSK panel RAFT1 Panels and Connectors New @ CDR

50. RAFT Critical Design Review 5023 Feb 2005 Interface Board

51. RAFT Critical Design Review 5123 Feb 2005 EPS and Solar Power Budget

52. RAFT Critical Design Review 5223 Feb 2005 Solar Power Budget Conclusion: The PCsat panels per side of the satellite and a 39% eclipse time, an average available bus load of 0.96 watts will be available to the spacecraft.

53. RAFT Critical Design Review 5323 Feb 2005 RAFT1 Required Power Budget Whole Orbit Average 10% Depth of Discharge

54. RAFT Critical Design Review 5423 Feb 2005 MARScom Required Power Budget

55. RAFT Critical Design Review 5523 Feb 2005 Power System

56. RAFT Critical Design Review 5623 Feb 2005 Simplified Power System Charge in Parallel Transmit in Series Duty cycle 4% 100 mA 60 mA

57. RAFT Critical Design Review 5723 Feb 2005 Charge in Parallel Transmit in Series Duty cycle 4%

58. RAFT Critical Design Review 5823 Feb 2005 Operations Safety Features All Transmitter circuits time-out to OFF

59. RAFT Critical Design Review 5923 Feb 2005

60. RAFT Critical Design Review 6023 Feb 2005 Battery Tests NiCd  No mass change, no leakage  Worst case 10% loss of capacity  Design Capacity has a 4 to 20 overdesign factor

61. RAFT Critical Design Review 6123 Feb 2005 PCsat Solar Panel I-V Curve discharged Full charge Angle

62. RAFT Critical Design Review 6223 Feb 2005 Post Cold Test Battery Condition (No Leakage)

63. RAFT Critical Design Review 6323 Feb 2005 Dead Battery Recovery Test

64. RAFT Critical Design Review 6423 Feb 2005 PCsat P-V Curve discharged Full charge

65. RAFT Critical Design Review 6523 Feb 2005 Frequency Coordination  RAFT1 ITU Request Form submitted. TX: 145.825 MHz, 2 Watt, 20 KHz B/W FMTX: 145.825 MHz, 2 Watt, 20 KHz B/W FM RX: 29.400-29.403 MHz PSK-31 ReceiverRX: 29.400-29.403 MHz PSK-31 Receiver RX: 145.825 MHz AX.25 FMRX: 145.825 MHz AX.25 FM 216.98 MHz NSSS transponder216.98 MHz NSSS transponder  MARScom DD 1494 submitted. 148.375-148.975 MHz VHF cmd/user uplink148.375-148.975 MHz VHF cmd/user uplink 24-29 MHz Downlink24-29 MHz Downlink 300 MHz UHF YP Craft Uplink Whip300 MHz UHF YP Craft Uplink Whip  Resonate at 216.98 MHz

66. RAFT Critical Design Review 6623 Feb 2005 Radiation Hazard = None Deployed and Active 11 V/m Pre-Separation 0.11 V/m Antennas Compressed, Shorted, Shielded and Sep-SW OFF

67. RAFT Critical Design Review 6723 Feb 2005 Material Status  Material On Hand: All flight ReceiversAll flight Receivers All flight TransmittersAll flight Transmitters All flight TNC'sAll flight TNC's All Electronic Components from stockAll Electronic Components from stock All ConnectorsAll Connectors All wire and cablesAll wire and cables  Manufactured: 4 Diagonal Corner Brackets4 Diagonal Corner Brackets  On Order (delivery any day now): All Solar PanelsAll Solar Panels All Nicad CellsAll Nicad Cells  To be Ordered: Flight TNC ROMS (after engineering model testing)Flight TNC ROMS (after engineering model testing) Flight Interface PCBFlight Interface PCB

68. RAFT Critical Design Review 6823 Feb 2005 Material Status (cont.)  To Be Manufactured: 2 top panels2 top panels 2 Bottom panels2 Bottom panels 2 B1 panels2 B1 panels 2 B2 panels2 B2 panels 2 RX panels2 RX panels 2 TX panels2 TX panels 4 Ant PCB and spring assemblies4 Ant PCB and spring assemblies 2 sets HF antenna boards2 sets HF antenna boards 2 HF flight antenna spool assemblies2 HF flight antenna spool assemblies

69. RAFT Critical Design Review 6923 Feb 2005 Shuttle Safety Requirements  Fracture Control Plan Captive & Redundant  Fastener integrity Captive & Redundant  Structural model of RAFTIdeas model, Buckling  Venting analysisDone. 0.04 “  Simple mechanismsAntennas  Materials / OutgassingCOTS, Replace Electrolytics  Conformal coat PC boardsYes  Wire sizing and fusing#24, fuse 1 amp  Radiation hazardBelow 0.1v/m  Battery safetyYes  Shock and vibrationYes

70. RAFT Critical Design Review 7023 Feb 2005 Battery Safety Requirements  Must have circuit interrupters in ground leg  Inner surface and terminals coated with insulating materials  Physically constrained from movement and allowed to vent  Absorbent materials used to fill void spaces  Battery storage temperature limits are -30°C to +50°C  Prevent short circuits and operate below MFR’s max  Thermal analysis under load and no-load  Battery must meet vibration and shock resistance stds  Must survive single failure without inducing hazards  Match cells for voltage, capacity, and charge retention

71. RAFT Critical Design Review 7123 Feb 2005 Questions?

72. RAFT Critical Design Review 7223 Feb 2005 Backup Slides

73. RAFT Critical Design Review 7323 Feb 2005 -60 °C Battery Tests Triple walled chamber Sealed for condensation Adding Dry Ice 30 Hour test @ -60C

74. RAFT Critical Design Review 7423 Feb 2005 -60 °C Battery Test: Thermal Conditions

75. RAFT Critical Design Review 7523 Feb 2005 Post -60 °C Charge Temp in Vacuum

76. RAFT Critical Design Review 7623 Feb 2005 Post Cold Test Discharge Current 852 mA-H

77. RAFT Critical Design Review 7723 Feb 2005 Dead Battery Charge Efficiency

78. RAFT Critical Design Review 7823 Feb 2005 Back

79. RAFT Critical Design Review 7923 Feb 2005 Back

80. RAFT Critical Design Review 8023 Feb 2005 Back

81. RAFT Critical Design Review 8123 Feb 2005 Back

82. RAFT Critical Design Review 8223 Feb 2005 Back

83. RAFT Critical Design Review 8323 Feb 2005 Back

84. RAFT Critical Design Review 8423 Feb 2005 Back

85. RAFT Critical Design Review 8523 Feb 2005 Back