1. Structures
March 13, 2004

2. 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

3. 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
Colorado Space Grant
Consortium

4. 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, unless approved.
Components may not be greater then 3in deep without prior approval from Structures and Systems
Colorado Space Grant
Consortium

5. ICU Envelope
Colorado Space Grant
Consortium

6. Main Structure Mass: 3.93kg Height:12.5in Diameter: 17.76in
Material: Al 6061
Similar design to Three
Corner Satellite
Envelope may be exceeded if FITS is too Large. If this is the case, solutions are lined up.
Colorado Space Grant
Consortium

7. Main Structure
Max Solar Array Size
Colorado Space Grant
Consortium

8. Nadir Plate
Colorado Space Grant
Consortium

9. Zenith Plate
Colorado Space Grant
Consortium

10. Side Panels
Colorado Space Grant
Consortium

11. FEA
March 13, 2004

12. Structure Specification
Material:
Aluminum 6061 for all components.
Specifications:
The structures (first mode) Natural Frequency should be beyond 100 Hz .
Colorado Space Grant
Consortium

13. 3-D Analysis for DINO side panel
Software's:
COSMOS Works 7.0
ANSYS 7.1
Analysis done in both software's.
Technical Limitations faced.
Colorado Space Grant
Consortium

14. Plots for modal analysis for side panel
Plots with COSMOS Works 7.0
The first mode was
observed at 277Hz.
Factor of safety of 2
for structure.
Colorado Space Grant
Consortium

15. Displacements plots for the Side Panel
Displacement Plot using Solid mesh.
The maximum displacement was observed to be 123 inches at the center portion of the panel at its first mode.
Colorado Space Grant
Consortium

16. Ansys Vs COSMOS Works The model for Ansys was checked for 2-D.
The plots of side panel using Ansys.
The first mode was observed at 106 Hz.
Merely meeting requirements.
Colorado Space Grant
Consortium

17. Checking with COSMOS Works
Shell mesh used for analysis check.
The first mode was observed at 265 Hz.
Also, proved to be giving a factor of safety of 2.
Discussion.
Colorado Space Grant
Consortium

18. Displacements for Side Panel
The displacements are for Side Panel with shell mesh.
The maximum displacement was observed to be 125 inches.
Colorado Space Grant
Consortium

19. Analysis of Nadir Plate
The nadir plate and the outer box were analyzed only in COSMOS Works.
The first mode occurred at 554 Hz.
A factor of more than 5.
Colorado Space Grant
Consortium

20. Displacements Plots for Nadir Plate
The displacement plot for the assembly was for the first mode with solid mesh.
The maximum displacement was seen to be 276 inches at the first mode.
Colorado Space Grant
Consortium

21. Vision
The structure should do well as a whole since the modes occur at higher frequencies due to cumulative mass of the system.
Further analysis of the structure needs to be done, optimization shall be the next step once we are done with the requirements of the structure.
Analysis will be done with COSMOS Works and Ansys even though ,the latter is available as Educational License.
Colorado Space Grant
Consortium

22. Boxes
March 13, 2004

23. Introduction Subsystem box designs include Safety Accessibility
Boxes are designed to protect and secure components
Accessibility
There is enough space in each box for circuit boards and wires
Holes will be added as needed
All sockets are accessible
Colorado Space Grant
Consortium

24. Changes since PDR
The C&DH and ADCS boxes were made into two separate boxes due to a dimension change.
The Camera box dimensions were increased.
Colorado Space Grant
Consortium

25. Design Overview ADCS C&DH Science Comm Power
Magnetometer PCB
C&DH
Science
Camera
Comm
Radio & TNC
Power
28V battery
Boxes attached to isogrid side panel
Magnetometer PCB
C&DH
TNC
28V Battery
Boxes attached to isogrid bottom panel
COMM-radio
Camera
Colorado Space Grant
Consortium

26. ADCS
4.4 x 4.4 x 1.75 in.
The x and y dimensions are 1 inch larger for isogrid attachment.
The Connector can be placed on any side of the box.
Colorado Space Grant
Consortium

27. ADCS Magnetometer PCB 2.5 x 2.5 x .75 in.
The location of the socket is accessible
Colorado Space Grant
Consortium

28. C&DH
4.5 x 4.5 x 5 in.
Houses the Arcom Viper Flight Computer and Interface Boards
Colorado Space Grant
Consortium

29. Camera Box
8.64 x 6.75 x 4 in
7.5 degrees angles pointing down opposite direction
Double mounting panel to secure the lenses
Colorado Space Grant
Consortium

30. COMM Radio Box
6.25 x 5.4 x 1.5 in.
1 additional RS-232 serial port to initialize radios
Colorado Space Grant
Consortium

31. COMM TNC Box Dimensions 6.1 x 7.3 x 1.3 in. 1 RS-232 serial port
Colorado Space Grant
Consortium

32. 28V Battery 2.4 x 4.3 x 2.15 in. Designed for a tight
fit on the x-axis at
2.4 in.
0.1 in. thickness
0.5 in. space
Colorado Space Grant
Consortium

33. Manufacturing and Test Facility Requirements
Manufacturing Requirements
CAD
Machine Shop
CNC/ CNC lathe and mill
Test Facility Requirements
Solidworks FEM analysis
Colorado Space Grant
Consortium

34. Conclusions Box Holes Camera Box Securing camera lenses Battery leak
These will need to be added when the different subsystems are positive of their location and size
Camera Box
The camera box dimensions will be adjusted
Securing camera lenses
Dimensions might need to be changed to prevent cracks in the lenses
Battery leak
The cover should be designed to with hold this occurrence
Small changes in the box dimensions will occur
Colorado Space Grant
Consortium

35. Testing and Budget
March 13, 2004

36. Early Testing FEA Envelope Verification Mass Properties
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

37. Testing Plans
Colorado Space Grant
Consortium

38. 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

39. 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 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
Colorado Space Grant
Consortium

40. Budgeted Side Panels 15 $18.57 $278.55 Bulkheads 4 $130.00 $520.00
Component
Quantity
Unit
Price
Total
Side Panels 15
$18.57
$278.55
Bulkheads 4
$130.00
$520.00
Boxes 30
$80.00
$2,400.00
Fastners
2000
$0.75
$1,500.00
Anodizing 1
$500.00
Total:
$5,198.55
Colorado Space Grant
Consortium

41. Issues and Concerns Complete FEA Boxes Documentation
How is the composite top panel going to effect things?
Boxes
Design
Connector info
Lids built into isogrid?
Documentation
Colorado Space Grant
Consortium

42. Mechanical Ground Support Equipment

43. Overall View
Colorado Space Grant
Consortium

44. Purpose Assist assembly of satellite.
Allow easy integration of hardware, wiring, mechanisms, side panels.
Allow easy transportation.
Allow easy accessibility.
Colorado Space Grant
Consortium

45. 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

46. PDR MGSE
Colorado Space Grant
Consortium

47. Changes Since PDR Added in a safety bar for the long arm.
Implemented many “plates” to add to the strength and to lessen the need for drilling. Also, implemented a large plate, for simplicity, between the bottom plate and the “base” and between the satellite and the “cart.”
Added several attachment points for the top and the bottom plates.
Increased simplicity for the “base.”
Decreased budget by the additions made.
Colorado Space Grant
Consortium

48. Requirements Met Width of the satellite is 27.5”.
Flowering pattern present in MGSE.
MGSE allows up to, and no more than, 54 degrees of rotation.
Each side panel has 4 attachment points. The top panel has 8 attachment points. The bottom panel has 22 attachment points. (The satellite while assembled will have 22 attachment points.
Colorado Space Grant
Consortium

49. MGSE Schematics and Drawings
Colorado Space Grant
Consortium

50. Schematics and Drawings
Colorado Space Grant
Consortium

51. Schematics and Drawings
Colorado Space Grant
Consortium

52. Schematics and Drawings
Colorado Space Grant
Consortium

53. Rotation View
Colorado Space Grant
Consortium

54. Rotation View
Colorado Space Grant
Consortium

55. Parts and Price List:
Colorado Space Grant
Consortium