Right-Sized Nanosatellites: Finding the Sweet Spot between 3U/6U and ESPA June 9, 2015 Clint Apland (240) 228-0388 clint.apland@jhuapl.edu

Topics to Discuss Need and Motivation Express-class Space Vehicle Features and Benefits Payload Provisions and Suitability to Payloads with Significant Mission Utility Benefits of Rectangular Adaptor Systems First Generation Adapter System Second Generation Adapter System Future Work

Motivation for Express Class An intermediary mission class standard is needed between ESPA (181 kg) and 3/6U CubeSat (~4-12 kg), to: More optimally utilize excess LV secondary payload rideshare accommodation capability. Enable lower cost missions when ESPA-class not needed. Provide for more flexible and capable space vehicles than possible w/ 3U-6U CubeSat (physical) constraints: E.g., larger payloads, greater power generation, propulsion Permit more ready-use of COTS components and technologies. Poly-Picosat Orbital Deployer (P-POD) NASA Ames (3/6U) NLAS Dispenser Express Atlas V ESPA Configuration Initial top-down/bottom-up study performed by APL in 2010-11

Express Class: 25-75 kg Standardized Nanosatellite W/O Propulsion W/ Propulsion Provides a standard, flexible spacecraft interface compatible with multiple LVs: For secondary manifest: Space-X Falcon 1e/9/9H OSC Minotaur I/IV/V, Antares,Taurus XL ULA Atlas V, Delta IV LM/ATK Athena IIc For primary manifest: ORS Super-Strypi SMDC Nano-Launcher* DARPA ALASA* Bridges gap between 3U/6U and ESPA 26.4 cm (10.4 in) 55.8 cm (22 in) To be investigated as data becomes available 47.0 cm (18.5 in) 47.0 cm (18.5 in) Optional shroud alleviates concerns of primary Payload (PL) damage Protects/conceals contents from: Visual inspection Physical access and tampering Aero-heating, thruster plume thermal Acoustics and contamination EMI/EMC Launching high performance, reliable nanosatellites featuring inexpensive and reliable separation systems is possible over a wide selection of launch vehicles

Express Features and Benefits Configurations with or without propulsion. > 225 m/s ΔV chemical propulsion allows rideshare flexibility; enables formation flying and constellations. Non-propulsion is lower cost and accommodates larger payloads within standard volume. Multiple PL data interfaces. Allows >two independent payloads. Large payload volume. Propulsion: 6,500 cm3 (400 in3) Propulsion Extended: 35,000 cm3 (2100 in3) Non-propulsion: 20,000 cm3 (1200 in3) Size, shape and mass less constraining than CubeSats. Allows more use of COTS components, can still benefit from use of CubeSat components, appendages can protrude if necessary. Simplified Adaptor & Separation System Simple, proven, low cost, allows axial or radial deployment, easily adapted to any LV. Flyaway half of separation system can double as bottom deck of SV. Available shroud. Provides protected environment, prevents visual inspection, tamper-resistance prevents access.

Payload Provisions Nominal PL Mass: 21 kg w/o propulsion; 8 kg w/ propulsion Data processing capability may be supported by S/C C&DH Flexible S/C software architecture with encryption capability Time: 1 pulse per second, GPS referenced Solid State Recorder (Mass Memory) is scalable Nominal PL Power: Orbit Average (typical orbit): >10 W Peak: 100 W Available Voltages: Unregulated Bus: 28 V (24 to 33 V) Regulated: 3.3 V and 5.0 V @ >4 A; Adjustable Attitude Determination & Control: Full 3-axis (zero momentum) Control <0.1, Knowledge <0.03 Communications: Full duplex USB/S-band (DL >1 Mbps)

Express SERB Payloads Applicability Criteria: V < 20,000 cm3 (w/o prop.) P < 30 watts M < 15 kg Results: Suitable for 11 of 19 (58%) of candidate payloads from 2014 SERB list, and could accommodate every CubeSat payload

EELV, F-9/Heavy, Antares Accommodation: ESPA Nanosats & ESPA SVs on a ø62” ESPA ring (option for 3 at each ESPA port) B1194 PSR Atlas V Delta IV 5-m fairings 2x D1666 PSR CSA Flat Plate Adaptor & 3 SVs ESPA SV Falcon 9 C-29 Ring Atlas V Delta IV 4-m fairings Shrouded Option Antares (Figure courtesy of ULA) Clearance for Antennas, etc. Optional P-PODs on Moog-CSA ESPA 6U Mounts (SUMs) (Figure courtesy of Moog-CSA)

EELV, F-9/Heavy, Antares Accommodation: ESPA + FPA Nanosats & ESPA SVs On a CSA Flat Plate Adaptor B1194 PSR Atlas V Delta IV Falcon 9 5-m fairings ESPA SV 2x D1666 PSR Bottom View CubeSats (10) Atlas V Delta IV 4-m fairings C-13 Adaptor (between Centaur forward cone and CSA Flat Plate Adaptor) Moog-CSA Flat Plate Adaptor Antares The same mixed payload topologies and ride-share flexibility is possible with smaller LV

Express Adapter FY15 Prototype Improvements Several refinements and enhancements were made through additional detailed design, testing activities to: Increase space vehicle mass/volume accommodation: mass-CG curve raised Reduce parts count, simplify AI&T, lower costs Reduce adapter (baseplate) fly-away mass Increase customizability for specific SV equipment accommodations Reduce operations required for flight mate Increase scalability for larger-class space vehicles Next-gen design activities scheduled for 2015 Complete detailed design (Q2-3CY15) Prototype fabrication, separation & vibration testing (Q3CY15)

Express Adapter Prototype Hardware Full adapter system prototype designed, built and vibration tested US Patent 8939409 for an “Adaptor System for Deploying Small Satellites” Adapter w/ SV Baseplate Exploring opportunities for flight demonstration and characterization Z axis Adapter Deployment H/W Vibration Test Configuration (without shroud) Thermal Test Layout Shroud Assembly

Prototype Hardware Test Plan Vibration Test Configuration (without shroud) Test outline: Sine and Random Vibration Testing in each of 3 axes, each axis: Pre-test sine survey at .25g, Sine Sweep, Random Vibration, post-test survey Deployments at ±60C (to be scheduled for next-gen adaptor) Ambient pressure (nitrogen back-fill) Deployments in the direction of gravity Deployment characterization (to be scheduled for next-gen adaptor) Use 3rd party air bearing fixture Measure tip-off rates in axes parallel to separation plane Measure separation rate Z axis Thermal Test Layout

Design Overview Design is simpler, more reliable, more cost effective and requires less volume than a ring type separation system 2x 31-pin Separation Connector Low Shock Separation Nut (picture courtesy of HiShear Technology Corporation)

Benefits to Small Sats of Rectangular Separation Systems Square interface is more efficient than circular interface Small SVs are usually rectangular and don’t have the volume for center cylinder structural elements Most of the loads in rectangular SVs are concentrated in the corners Cylindrical separation systems are sensitive to load “peaking” To avoid load peaking, cylindrical interfaces require large and massive structures to distribute loads The rectangular adaptor is insensitive to load peaking; loads are reacted from SV corners into separation system corners The rectangular adaptor can be easily customized to be used as the bottom deck of the space vehicle Increases usable SV volume and decreases total system mass The rectangular adaptor is more cost effective than cylindrical adaptors Separation system is less costly than cylindrical systems Can eliminate the cost of SV bottom deck The rectangular adaptor is easier to set for flight than some cylindrical separation systems The rectangular adaptor can be used with “work- horse” LV-side GSE adaptors, unlike some cylindrical adaptors Other Features & Benefits: Simple and reliable Single machined deck from flat plate Much lower parts count than cylindrical adaptors Mechanism parts count dramatically reduced, as compared to cylindrical adaptors Separation nuts: Simultaneously actuated Low shock Reliable with heritage Non-explosive actuators are available Integral separation connectors Redundant Loop-back Break- wire separation indication No separation switch “chatter”

Future Work Continuing to Engage Sponsors Performing Mission Concept Studies Coordinating Experimental/Prototype Flight Missions in 2016 Seeking Industry Partners for Tech-Transfer of Express Dispenser APL’s role is not separation system hardware production Benefits our community Low cost, reliable, flexibly configured separation systems that reduce overall system mass and increase usable volume