CINEMA PDR- MEC 1 CINEMA Mechanical Subsystem PDR August 22, 2008 David Glaser/Paul Turin

CINEMA PDR- MEC 2 MECHANICAL -- Overview Mechanical Requirements Mechanical Subsystems Chassis Solar Array Communication Hardware Torque Coils Sun Sensor Magnetometer Boom STEIN Mass Budget

CINEMA PDR- MEC 3 MECHANICAL – Requirements Meet Cubesat Interface and Mass Specifications Withstand Launch Environmental Loads Keep Internal Magnetic Field to a Minimum Design Bus Chassis House All Components in Bus STEIN Instrument Attenuating Shutter Magnetometer Boom Deployment Mechanism Magnetometer Harness Harnessing (TBD)

CINEMA PDR- MEC 4 MECHANICAL – CubeSat Req. 1. CINEMA must fit inside a P-Pod (Poly-Picosatellite Orbit Deployer) and be deployed without jamming 2.No parts may separate from the satellite (no space debris created) 3.No pyrotechnics allowed 4.Maximum Mass: 3 kg (negotiable?) 5.Kill Switch, Deployment Switch, and Spring Plungers P-POD CAD Image KC-135 P-POD Test Video

CINEMA PDR- MEC 5 MECHANICAL -- Chassis inch thick Aluminum Sheet Metal Ends – ¼ inch Aluminum Rail Dimensions to Cubesat Specifications mm 100 mm Rails Hard Anodized

CINEMA PDR- MEC 6 MECHANICAL -- Chassis Deployment Switch Spring Plunger Spring Plunger

CINEMA PDR- MEC 7 MECHANICAL -- Overview Science Radio Transmitter Genesat Avionics Box Mag Boom Deployer Outboard Magnetometer Sun Sensors STEIN Components will generally be fastened with a #4-40 flathead screw, countersunk into chassis. Inboard Magnetometer

CINEMA PDR- MEC 8 MECHANICAL – Solar Array 10 Panels (3 on each long side 1 Panel on top, bottom, and short sides) Each Panel 3 x 3.2 inches (7.6 x 8.1 cm) Nominal Bus Voltage is 9.2 V Therefore need 4x PV cells on each panel Typical cells too large TASC cells are small enough, but require assembly, and have no coverglass

CINEMA PDR- MEC 9 MECHANICAL – Solar Array 1.55 cm (.61 inches) 3.18 cm (1.25 inches) TASC PV Cells (Spectrolab) 20 Cells/Panel 8 Panels Cost of Cells: $500 No Coverglass Included Cost of Assembly ?

CINEMA PDR- MEC 10 MECHANICAL - Communication Patch Antennas Science Data Transmitter Telemetry Transceiver 2 Science Data Patch Antennas 2 Telemetry Patch Antennas

CINEMA PDR- MEC 11 MECHANICAL – Torque Coils Coils located on STEIN Side and Bottom Torque Coil Rail

CINEMA PDR- MEC 12 MECHANICAL – Torque Coils 28 AWG Magnet Wire (0.32 mm diam./ max current 1.4 A) 62 Turns (50 m of wire) Coil Length: m Width: m Effective Coil Area: m 2 Electrical Resistance: 10.65Ω Bus VoltageCurrent (A)Am 2 Power (W)

CINEMA PDR- MEC 13 MECHANICAL – Sun Sensors Field of View Per Sensor: 5° Azimuth x 41° Elevation 2 45° to Vertical, 90° to Each Other Sensor: Phototransistor (Motorola MRD300) Prototype Tested Load Resistor: 1 kΩ Vcc = 5 V Power: ~25 mW (Light); ~10µW (Dark) 1.6 cm 2.3 cm

CINEMA PDR- MEC 14 MECHANICAL – Sun Sensors 4.6° > 1 Volt Rise Time ~120 ms Simulation of Earthshine Nominal 1.4° Width of Opening Prototype Scanned Across 1 RPM Averaged Data

CINEMA PDR- MEC 15 MECHANICAL – Sun Sensors Raw Data Noise ~ -0.3 V Slope of Rise: ~ 35 V/sec Timing Error = 9 ms < 0.1° Large Noise Peaks Probably Due to DC Motor

CINEMA PDR- MEC 16 MECHANICAL – Mag & Boom

CINEMA PDR- MEC 17 MECHANICAL – Mag & Boom 1 meter stacer boom Held by TiNi P5 Pin Puller Magnetometer in 2 x 2 x 2 cm compartment Magnetometer Harness 18 strands of 36 AWG magnet wire Aracon braid for Harness Jacket Non-Magnetic Braid on 6 cm closest to sensor Fixed to Mag Mount and Base of Boom via Screw-Down Fixtures 18-pin Connector at End

CINEMA PDR- MEC 18 MECHANICAL – Mag & Boom Magnetometer Chassis Mounts Magnetometer Mount

CINEMA PDR- MEC 19 MECHANICAL – Mag & Boom Stowed Stacer Boom Release Pin TiNi Pin Puller

CINEMA PDR- MEC 20 MECHANICAL – Mag & Boom Harness Details Harness Constraining Fixtures String Cannister

CINEMA PDR- MEC 21 MECHANICAL – Mag & Boom

CINEMA PDR- MEC 22 MECHANICAL – Mag & Boom Harness Assembly

CINEMA PDR- MEC 23 MECHANICAL – Mag & Boom Anti-vibration Clearance 0.02 inches (0.5 mm)

CINEMA PDR- MEC 24 MECHANICAL – Mag & Boom Prototype Harness 36 AWG Magnet Wire with Polythermalize Insulation Examined for Wear Under Microscope 18 Strands Wound with a winding machine, 1 turn/cm Tension on cable not controlled Inserted into Aracon Braid Harness Deploy Tested on Mockup Boom

CINEMA PDR- MEC 25 MECHANICAL – Mag & Boom Boom & Harness Mock Up – Stowed Configuration ID 2.54 cm Annulus 3.8 mm

CINEMA PDR- MEC 26 MECHANICAL – Mag & Boom Boom & Harness Mock Up – Deployment Test Video (half speed)

CINEMA PDR- MEC 27 MECHANICAL -- STEIN Collimator: 40° x 60° FOV High Voltage Plates: 4 mm separation, ~1 cm from detector Attenuator: Swinging Shutter with BeCu Foil Actuated by Two SMA “Nanomuscles” Flight Heritage from THEMIS and other Missions Low Electrical and Magnetic Noise Microswitch Overcenter Mechanism

CINEMA PDR- MEC 28 MECHANICAL -- STEIN Collimator Attenuator Detector and Electronics

CINEMA PDR- MEC 29 MECHANICAL -- STEIN Collimator Electric Field Plates 60°

CINEMA PDR- MEC 30 MECHANICAL -- STEIN Attenuator Shutter Shutter with BeCu Foil 4 Pixel Detector

CINEMA PDR- MEC 31 MECHANICAL -- STEIN Actuators – Shutter Closed Nanomuscle Actuator Capton Yoke Pivot Lever Cam/Lever Countermass

CINEMA PDR- MEC 32 MECHANICAL -- STEIN Actuators – Shutter Open

CINEMA PDR- MEC 33 MECHANICAL -- STEIN Attenuator Overcenter Mechanism HM Microswitch Cam Bearing Spring Plunger

CINEMA PDR- MEC 34 MECHANICAL -- STEIN Attenuator Mechanism Specifications NanomuscleSpring-Loaded Lever Nominal Stroke4 mmMech. Advantage5.92 Max. Force70 g (0.69 N)Roller Displacement0.89 mm Nanomuscle LeverPlunger Displacement0.79 mm Pivot Angle35°Spring Rad. w/ 4 mm stroke6.55 mmSpring Constant0.17 N/mm Rad. w/ 3.5 mm stroke5.73 mmFree Length15.75 mm Microswitch Actuation Force~0.98 N Spring Constant~0.5 N/mm Operating Stroke0.15 mm

CINEMA PDR- MEC 35 MECHANICAL -- STEIN Attenuator Mechanism Analysis Maximum Torque from Nanomuscle and Lever Stroke Lever Radius Tmax (mNm)FOS

CINEMA PDR- MEC 36 MECHANICAL -- STEIN Attenuator Overcenter Mechanism – Cam Analysis

CINEMA PDR- MEC 37 MECHANICAL -- STEIN Attenuator Overcenter Mechanism – Cam Analysis

CINEMA PDR- MEC 38 MECHANICAL -- STEIN Attenuator Mounting – How to Locate These Components

CINEMA PDR- MEC 39 MECHANICAL -- STEIN 1. Attenuator Mounting – Collimator Shell

CINEMA PDR- MEC 40 MECHANICAL -- STEIN 2. Attenuator Mounting – Add Mount Plate

CINEMA PDR- MEC 41 MECHANICAL -- STEIN 3. Attenuator Mounting – Add Shutter and Actuators

CINEMA PDR- MEC 42 MECHANICAL -- STEIN 4. Attenuator Mounting – Add Switch Mounts

CINEMA PDR- MEC 43 MECHANICAL -- STEIN 5. Attenuator Mounting – Add Switches #0-80 Set Screw for Switch Location Adjustment

CINEMA PDR- MEC 44 MECHANICAL – Mass Budget Subsystem/PartProposalPDR Chassis Solar Arrays375 MAG Boom System Sun Sensors10 Antennas15165 Genesat Avionics 1 battery pack950 2 battery packs?? Transmitter70 Torque Coils5085 STEIN Detector Head70146 STEIN Electronics90 STEIN HVPS150 MAG Electronics45 Instrument Digital90 Instrument LVPS150 Harnessing60 Thermal50 Total Highlighted figures Have changed since the proposal. Most other figures are rough estimates.