ZAMBONI

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ZAMBONI

• Zippy Aerospace Module Broadcasting
• Observed Not-so-bad Images
• Senior Design Presentation

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DesignTeam

• Mechanical Engineering
• Jon Fargo
• Katie Kirchner
• Andrea Mattern
• Electrical Engineering
• Mike Hoffmann
• Jon Lovseth
• Chris Schmidt
• Jason Senti
• Warren Wambsganss
• Faculty
• Arnie Johnson
• Richard Schultz
• Will Semke
• Chang-Hee Won

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KatieKirchner
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What is a CubeSat

• Idea originated at
• Stanford University by
• Professor Robert Twiggs
• California Poly
• responsible for
• launch integration

Size 10 cm (4) Cube Mass 1 kg
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Mission

• Successfully build and launch a CubeSat
• Transmit a single digital image from space
• and receive the image on Earth

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Goal

• Orbit Earth for approximately 8 months
• Transmit numerous digital images to Earth
• Transmit health/status data to Earth
• Transmit data from a commercial/
• government sponsored payload to Earth

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System Overview
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Specifications

• Structure Material
• Aluminum 6061 or 7075 suggested
• Must have same coefficient of thermal
  expansion as Aluminum 7075 (P-POD)
• Tolerances of 0.1 mm
• All edges must be rounded with 2 mm radius
• Dimensions given for all outer surfaces
• Legs
• Outer Rails

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Frame Design Ideas
Modular Cube Design

• easy access
• solar cells not attached
• until very end
• testing problems
• difficult to machine

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Frame Design Ideas
Thin Frame Design

• access to interior
• easy to machine
• thick enough for screws
• solar cells can be
• included in testing
• high mass

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Frame Design Ideas
Square Hollow Tube Design

• solar cell attachment
• easy to machine
• mounting of
• components on interior
• no access to the interior

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Frame Design Ideas
Modular Four Rail Design

• lightweight
• access to interior
• good for tolerances
• mounting of
• components on interior
• many different parts
• to machine

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JonFargo
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Mass Budget
oz. gm.
Communication / Control Transceiver (and antenna) w/o batts or case 2.08 59
Communication / Control TNC 2.01 57
Communication / Control Microcontroller    
Communication / Control Circuit Board est 6.00 170
     
Power Solar cells (1_at_8g) 28 cells 7.90 224
Power Li Ion batteries est 6.70 190
Power Battery charging circuitry  incl. incl.
Power Voltage regulators  incl. incl.
Power    
     
Attitude Control Passive magnet 1.27 36

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Mass Budget
Sensors Temperature sensors  incl. incl.
Sensors Voltage sensors incl. incl.
Sensors Current sensors  incl. incl.
Sensors 2 Digital cameras w/o batteries or case (1_at_96g) 6.77 192
     
Structure Aluminum frame est. 17.64 500
     
Payload Allotted mass 10.58 300
   
  20 Margin 14.11 400
  Total 75.06 2128
  Budgeted Mass 70.55 2000
  over/under budget 6.40 6.40
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SizeBudget

• Total volume available
• 10 1020 cm 2000 cm3
• Total Volume Used
• 680.3 cm3
• 66 Volume Remaining
• Does not include wires and
• other misc. connections

Major Components Major Components Major Components    
cu. in. cu. cm. cu. in. cu. cm. cu. in. cu. cm. cu. in. cu. cm. cu. in. cu. cm.
Ham Radio 2.88 45 45 45
TNC 9.28 152.38 152.38 152.38
Li Ion Batteries 3.061 50.92 50.92 50.92
Digital Camera - x 2 26.62 432 432 432
Frame 118.64 2000 2000 2000
Payload ¼ volume 29.66 500 500 500
         
Total Volume 41.841 680.3 680.3 680.3
Remaining Volume 47.139 819.7 819.7 819.7
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Prototypes

• Rapid Prototyping Machine
• Full size and scale models
• ABS Plastic

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P-Pod

• Aluminum 7075-T6
• Spring Deployed
• Heat activated
• line cutter
• Internal railings
• Interface port
• (access CubeSat
• while in P-Pod)

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Testpod

• Internal Dimensions same as launcher tube
• Will accommodate double and triple cubes
• Designed and manufactured at UND

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Testpod

• Launch Condition Testing
• Needs two mounting plates
• Bolts to Shaker table

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Testing

• Standard 5.0 cu. ft freezer
• Desired temp -40 C
• Achievable temp -37 C,
• -67 C with dry ice
• Relay equipped for
• DAQ card control
• Temperature sensors
• throughout freezer

Cold Thermal Testing
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Testing

• Vacuum Chamber

• Custom built from acrylic by
• Plastics Plus Bismarck, ND
• 5.5 inside diameter
• Can achieve vacuum of less
• than 0.2 inches of mercury

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AndreaMattern
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Testing
Vibration Testing

• Shaker Table
• MB Dynamics C10E shaker M6K amplifier system

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Testing
Vibration Testing

• Launch Vehicle Unknown
• Vibration and Qualification
• Test at UND
• 125 Launch Loads
• 12.5 Grms maximum
• Sine Sweep
• 50 Hz to 2000 Hz
• Random Vibrations
• /-6 dB/oct abort limits

Random Vibration Levels for Various Launch
Vehicles
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Testing
Vibration Testing

• Vibration Acceptance Test
• at Calpoly
• 100 Launch Loads
• 10 Grms maximum

Random Vibration Acceptance Test Levels Random Vibration Acceptance Test Levels
Frequency (Hz) Acceptance PSD Level (G2/Hz)
20 0.013
20-50 6 dB/oct
50-800 0.08
800-2000 - 6 dB/oct
2000 0.013
Overall 10.0 Grms
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Testing
Adhesive Testing

• 3M Scotch-Weld Epoxy Adhesive, 2216 B/A Gray

• Purpose
• 1. Verify adhesive properties for Cubesat
  applications
• ? Securely adhere solar cells to
• aluminum, varying thicknesses
• ? Insulate solar cells from conductive
• structure with layer .005 thick
• 2. Create Procedures
• ? Surface preparation
• ? Mixing/Application
• ? Accelerated curing
• ? Pre-cured layer application

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Finite Element Analysis
Preliminary Analysis

• Three Rail Models
• 1. Rail with circular holes
• 2. Rail with square holes
• 3. Rail with no holes
• Conditions
• Axial loading
• Static maximum testing load 18Gs
• Constrained on bottom surface for all DOF
• Free mesh
• Solid 187 and Solid 45 elements used

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Finite Element Analysis
Rail with Circular Holes Rail with Circular Holes
Maximum Stress Value .307E7Pa 445psi
Location of Maximum Stress Cubed ends meet holed sections
Safety Factor  83,062
Rail with Square Holes Rail with Square Holes
Maximum Stress Value .303E7Pa 439psi
Location of Maximum Stress Cubed ends meet holed sections
Safety Factor  84,158
Rail with No Holes Rail with No Holes
Maximum Stress Value .320E7Pa 464psi
Location of Maximum Stress Cubed ends meet holed sections
Safety Factor  79,688
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Finite Element Analysis
Future Analysis

• Create entire model in ANSYS
• Rail with square holes
• Mapped mesh
• Solid 45 elements
• Simulate launch and test loads
• along the x, y, and z axes

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JonLovseth
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Components

• Camera
• Olympus D-360L
• Microcontroller
• MSP430F149
• TNC
• PicoPacket (replaced)
• Radio
• Yaesu Vx-1R

Hamster for power
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Interface
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Fullpic3
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Subliminal Message
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Not-so-badImages
Thumbnail 4kbytes
SQ resolution 50-64kbytes
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Things to Keep in Mind

• Component overheating
• Half Duplex data transfer
• Buffer size
• Link budget
• Download opportunities

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MikeHoffmann
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Ground Station

• Data received in hexadecimal
• Contains header and
• footer information
• (must be parsed)

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Ground Station
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Image Reception

• Header and footer
• analyzed to determine
• how to process image
• Remaining image data
• is output as a viewable
• JPEG image

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Image Reception
Ground Station
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Image Reception
Ham Radio Info is Removed
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Image Reception
UND header is interpreted and removed
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Image Reception
End of File Indicator is interpreted and removed
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Image Reception
Packet headers are interpreted and removed
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Image Reception
Image is displayed
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WarrenWambsganss
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Attitude Control
Decreasing Complexity

• Magnetic torque rods
• Uses magnetic torque to
• point satellite
• Gravity gradient
• Uses boom (weight) to align with
• Earths gravity gradient
• Magnetic alignment
• Makes use of a magnet to align
• with the Earths magnetic field

Active
Passive
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Active Control

• Relies on global position system data (GPS)

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Magnetic Alignment

• Extremely strong
• Rare-Earth magnets
• Larger magnets
• produce more torque
• Probability of seeing
• Earth increases from
• 95.88 to 99.25 at
• 800 km orbit

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Attitude Control

• Orientation with magnetic alignment

Picture footprint
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SolarCells
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Solar Cells

• Need more Voltage?
• Connect in series
• Need more current?
• Connect in parallel
• Use combinations of both for array

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SolarCells

• Most efficient if operated at the maximum power
  point

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SolarCells

• Normalized power resulting from ZAMBONI geometry

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Power Subsystem

• Unregulated battery charging
• Connect battery directly to solar cells
• Battery charging range of 6.4 to 8.4V
• Max solar cell voltage of 8V
• 4 in series (1 small side)
• Disadvantages
• Solar cells do not operate efficiently
• Cannot fully charge battery
• Damaged cell can disable entire side
• Advantages
• Simple to implement

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Power Subsystem

• Boost regulated charging with set point
• Maintains cells at max power operating point
• Advantages
• Solar cells operate more efficiently
• Damaged cell only disables half of small side
• Can charge battery over full range
• Disadvantages
• More complex circuitry
• Have to account for change in solar cell
  efficiency due to change in temperature

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Power Subsystem

• Boost regulated with dynamic set point
• Uses microcontroller to maintain max power output
• Advantages
• Accounts for changes in cell efficiency
• Can be used on any array of similar of similar
  size without adjustment
• - Future CubeSats
• Disadvantages
• Complex system
• - More things can go wrong

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Power Subsystem

• Sets the operating point of solar cells (Boost
  converter 90 efficient)

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Power Subsystem

• Small board (2.5 by 3 inches)

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AIAA

• American Institute of Aeronautics and
  Astronautics
• Unites UND Aerospace, Space Studies,
• and Engineering students
• Access to UND Student Organization funding
• Tentative UND AIAA Student Branch, January 2003

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Special Thanks

• Dr. John Ettling, V.P. of Academic Affairs and
  Provost
• Prof. Arnie Johnson, Chair of Electrical
  Engineering
• Dr. Donald Moen, P.E., Chair of Mechanical
  Engineering
• Dr. John Watson, Dean School of Engineering and
  Mines
• Dr. Shanaka de Silva, North Dakota Space Grant
• Intercollegiate Academics Fund (VPAAs Office)

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Yet to be done

• Integration of components within the satellite
• Uplink telecommand integration
• Conformal coating for electronic components
• Shock absorbers for the components
• Actual build of satellite
• Testing Completed
• Thermal
• Vibration
• Vacuum

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ZAMBONI

• Zippy Aerospace Module Broadcasting
• Observed Not-so-bad Images
• Senior Design Presentation

QUESTIONS?