CalSat
Gerald Frolich – Project Manager / ElectronicsDavid Baroff – SystemsDickson Yuen – ManufacturingSeth Drake – Attitude Control / Electronics
[1]
Mission Objectives
To design and build a 1U(10x10x11cm) CalSat to calibrate/validate NASA’s CubeSat test environment.
To work with JPL in the review of the CubeSat’s existing test requirements and to increase reliability on CubeSat mission success, in light of its Class D classification.
[2]
Program Requirements (Level 1)
The project will survey existing maximum predicted environments (MPE) and develop a MPE mission set for approved CubeSats.
Establish a set of labs that can be used to teach spacecraft (i.e. CubeSat) design using CalSat and qualify the University CubeSat environmental testing equipment.
[3]
Program Requirements (Level 1)
CalSat will adhere to CubeSat.org “CubeSat Acceptance Checklist” regarding CubeSat physical properties as defined in revision 12 (August 1, 2009; Riki Munakata)
[4]
Program Requirements (Level 1)
CalSat will comply with the General Environmental Verification Standard (GEVS) requirements established by NASA as defined in LSP-REQ-317.01 Revision B (January 30, 2014; Amanda Mitskevich)
[5]
Project Requirements (Level 2)
The chassis will be constructed using aluminum 7075, 6061, 5005, and/or 5052 for both the main CalSat structure and the rails.
[6]
Project Requirements (Level 2)
Be able to measure and withstand random vibration of MPE plus 6 dB for 3 minutes, on all 3 axes.
Be able to measure and withstand sinusoidal vibration of MPE plus 6 dB for content that is not covered by random vibration testing.
Survive and record testing of shock of MPE plus 6 dB on all 3 axes.
Demonstrate survivability for all types of radiation determined by the mission profile set.
Will measure change in acceleration on 3 axes. Can withstand and measure temperatures in the
minimum range of -14°C to 71°C or MPE +/- 10°C. Will measure and record pressure determined by MPE.
System Requirements (Level 3)
Will use a vibration sensor to measure random/sinusoidal vibration on the CalSat.
Will use an accelerometer to measure shock and acceleration on the CalSat.
Radiation exposure levels on the CalSat will be measured using a dosimeter.
Temperature will be measured with a temperature sensor. Change in pressure will be sensed using a vacuum sensor. Batteries must last a minimum of 3 hours to complete
testing.
CubeSat Kit
Electronics: Motherboard,
Development Board and Pluggable Processor Modules
Wireless and Wired Communications
CubeSat Kit Bus Flexible Power Module
Compatibility Mass Storage
Software CubeSat processor
specific library for motherboard interface
Pumpkin Salvo Pro Real-Time Operating System
Kit components: Structure
Modular Chassis – Aluminum, solid wall, adheres to CubeSat standards
[7]
CubeSat Chassis
Made with Aluminum Alloy 7075-T6 Modular, skeletonized or solid wall Space proven (over 30+)
Mass: Skeletonized:
71 gramsper wall
Solid: 132 grams
per wall
[8]
CubeSat Motherboard
Single Board Computer for Harsh Environments PPM (pluggable processor module) I2C, USB 2.0, SD Card socket Mass: 77 grams , Suitable for temps:
-40C to +85C Operating specs:
0.5 mA, 1.65V 104 I/O pin connectors Designed to install
seamlessly into Pumpkin CubeSat chassis
[9]
Battery Pack
High Capacity Battery Pack designed for Nano-Satellites 8.4V, 5200mAh (or 16.8V, 2600mAh) 4 Li-Ion cells Built-in Thermal Sensor Stackable for increased capacity Dimensions: 94 x 88 x 23 mm Mass: 240 grams
[10]
Dosimeter
Highly Sensitive, Low Power Radiation Monitoring Measure Radiation Levels (total ionizing dose) - Range: up to 40kRads
Manufacturer: Teledyne Microelectronics Dimensions:
1.4” x 1.0” x 0.040” Weight:
20 grams Power consumption: 10 mA @ min13-max40V
[11]
Accelerometer / Shock Sensor
Honeywell QA-3000 Accelerometer Inertial sensor developed for spacecraft navigation systems
Analog output Input: +/- 60 G
Accurate within .004 G Mass: 71 grams
Dimensions : 2.56cm x 1.49 cm
Stainless steel casing Environmentally rugged
-28C to 78C operating temps Withstand shock up to 100G[12]
Vibration Sensor
Columbia Research Labs 972 V5 Vibration/Temperature Transmitter Two Signal outputs, vibration level and temperature Accuracy:
0-50 G peak vibration +/- 1.5 degrees C
Two casing designs H1, H2 Mass:
H1 – 150 grams; H2 – 230 grams
Dimensions: H1 – 3.81 cm x 3.8 cm x 2.67 cm H2 – 3.18 cm diameter x 6.35 cm
Operates at 10V, 4 mA[13]
Force Sensor
FSS-SMT SeriesFSS020wngx Force sensing
range: 0-20 N Surface
mountable Operates at -40
C to +85 C Shock tested to
150 G Stainless steel
ballfor force compression
Vacuum Sensor
Stellar Tech IT30 Intelligent Pressure Transducer Operates at min. 8V, ~25mA Dimensions: 8.51 cm x 3.81cm Range: 0-30,000 PSI
Accurate within 0.1% Stainless steel Designed for harsh
environments: -40 C to +185 C
Fast sampling (100Ks/s)[15]
Power / Mass Budget
Item Mass (g) Current (mA) Voltage(V) Power (mW)CubeSat Kit/ MSP430, Skeletonized-Wall 1 U 436 N/A NA N/AMotherboard (MB) 77 0.5 1.65 0.825Delkin Industrial temperature range 2GB SD Card 9 0 0 0Microcontroller 35 200 2.7 540Nano Power Battery Pack 240 N/A N/A N/ADosimeter 20 10 13 130Accelerometer / Shock Sensor 71 16 13 208Vibration Sensor 150 4 10 40Force Sensor TBD 1.2 6 7.2Pressure (Vaccuum) Sensor 255 25 8 200Total 1283 256.70 1126.03W/(15% Margin) 1475.45 295.21 1294.93
Chassis Material Trade Off Study
7075-T6 Aluminum between 87.2-91.4% Zinc between 5.1-6.1% Magnesium between 2.1-2.9% Copper between 1.2-2.0% Density 2.8 g/cm3
Strength-to-weight ratio 211kN-m/kg Most expensive
6061-T6 Aluminum between 95.9-98.6% Magnesium between .8-1.2% Silicon between .4-.8% Iron between 0-.7% Density 2.7 g/cm3
Strength-to-weight ratio 115kN-m/kg
5005 Aluminum between 97.0-99.5% Magnesium between .5-1.1% Iron between 0-.7% Density 2.7 g/cm3
Strength-to-weight ratio 85kN-m/kg
5052 Aluminum between 95.8-97.7% Magnesium between 2.2-2.8% Iron between 0-.4% Density 2.68 g/cm3
Strength-to-weight ratio 116kN-m/kg
[16]
Detailed CostItem Cost Part Number Seller Comments
CubeSat Kit/ MSP430, Skeletonized-Wall 1 U $7,500 711-00282 PumpkinSat Chasis and Programming Tools Pumpkin Salvo Pro (TI's MSP430) 709-00217 PumpkinSat Included in Kit Pumpkin MSP430 CubeSat Kit Software 709-00332 PumpkinSat Included in Kit HCC-Embedded MSP430 EFFS-THIN SD Card Library 709-00371 PumpkinSat Included in Kit Pumpkin JFPC-MSP430 Programming Adapter 634-00334 PumpkinSat Included in Kit TI MSP430 USB Flash Emulation Tool 633-00299 PumpkinSat Included in Kit Pumpkin MSP-TS430PM64 Adapter 710-00509 PumpkinSat Included in Kit Pumpkin Pluggable Processor Module A1 710-0485 PumpkinSat Included in KitDevelopment Board (DB) $1,300 710-00297 PumpkinSat Motherboard (MB) $1,200 710-00484 PumpkinSat Delkin Industrial temperature range 2GB SD Card $180 634-00456 PumpkinSat Range of -40C to +85CMicrocontroller $17 MSP-EXP430FR5969 TI Nano Power Battery Pack $2,014 BP4 GOMSpace Includes Temperature SensorExternal Power Supply 5Vdx, 4A $60 632-00298 PumpkinSat Motherboard SupplyExternal Power Supply 6-12Vdx $60 632-00413 PumpkinSat Development Board SupplyDosimeter TBD UDOS001 Teledyne Measures up to 40k RadsAccelerometer / Shock Sensor TBD QA3000 Honeywell (+/-) 60G and 100G ShockVibration / Temperature Sensor TBD 972-V5-H1 Columbia R.L. 0-50 GForce Sensor TBD FSS-SMT Honeywell 0-20 NPressure (Vacuum) Sensor TBD IT30XX Stellar Tech. 0-30,000 PSIPelican Ruggedized Transport Case $200 632-00372 PumpkinSat Not Included In BudgetPersonalized Training (per hour) $350 713-00373 PumpkinSat Not Included In BudgetDVC 1 Desktop Vacuum Chamber 1 natural aluminum base $8,995 711-00652 PumpkinSat Not Included In BudgetTotal $12,331After Tax $13,317After Tax W/(600% Margin ) (estimate $2,000-$15,000 a sensor) $79,904.82
Prototype Model
Prototype Model
Prototype Model
Block Diagram
Power / Mass Budget (Model)
Item Mass (g) Current (mA) Voltage(V) Power (mW)
PLA Filament 65 N/A N/A N/A
Arduino Mega 2560 R3 34.9 50 5 250
Data Logging Shield 22 14 5 70
SanDisk 8GB Memory Card 8.5 0 0 0
Li-Ion Battery 90.7 N/A N/A
Geiger Counter 30 30 5 150
Vibration Sensor 0.6 0.022 5 0.11
Optical Dust Sensor 16 20 5 100
10 Degrees of Freedom IMU 2.8 5.115 5 25.575
Slow Vibration Sensor Switch 0.3 20 5 100
Fast Vibration Sensor Switch 0.3 20 5 100
Total 271.10 159.14 795.69
W/(15% Margin) 311.77 183.01 915.04
Interface Definition
Battery Trade Off Study (Model)LITHIUM-ION
Pros High energy
density Low self-discharge
(Less then half that of NiCd and NiMH)
Cons Requires battery
protection circuit Moderate
discharge current Subject to aging,
even if not in use
NICKEL-METAL-HYDRIDE
Pros Environmentally
friendly 30-40% higher
capacity in energy density then NiCd
Cons Recommended to use
with load currents between .2C - .5C
High self-discharge (Can have lower self-discharge, but will lose energy density)
Generates more heat and requires longer charge time compared to NiCd
Pros Long shelf-life, in
any state-of-charge
Most dependable batteries
Fast and simple charge
Cons Lowest energy
density of the three
Environmentally unfriendly
High self-discharge
NICKEL CADMIUM
[17]
Detailed Cost (Model)
Item Cost Cost Per Unit Quantity Part Number Seller
PLA Filament None N/A N/A N/A Self
Arduino Mega 2560 R3 $45.95 $45.95 1 11061 Sparkfun
Data Logging Shield $19.95 $19.95 1 1141 Adafruit
SanDisk 8GB Memory Card $5.95 $5.95 1 N/A Amazon
Li-Ion Battery $13.99 $13.99 1 N/A Amazon
Geiger Counter $149.95 $149.95 1 11345 Sparkfun
Vibration Sensor $2.95 $2.95 1 9198 Sparkfun
Optical Dust Sensor $11.95 $11.95 1 9689 Sparkfun
10 Degrees of Freedom IMU $59.90 $29.95 2 1604 Adafruit
Slow Vibration Sensor Switch (Hard to trigger) $1.90 $0.95 2 1767 Adafruit
Fast Vibration Sensor Switch (Easy to trigger) $1.90 $0.95 2 1766 Adafruit
Total $314.39
After Tax $339.54
After Tax W/(25% Margin) $424.43
Schedule
Schedule
Schedule
Appendix: Sources
1. http://www.nasa.gov/images/content/429961main_cubesat_1.jpg2. http://upload.wikimedia.org/wikipedia/commons/7/73/ F-
1_CubeSat_thermal_vacuum_test.jpg3. http://wallpaperank.com/wp-content/uploads/2013/10/Outer-Space-NASA-
Wallpaper.jpg4. http://dww.cubesat.org/images/developers/cac_rev12.pdf 5. http://www.nasa.gov/pdf/627972main_LSP-REQ-317_01A.pdf 6. http://www.cubesatkit.com/images/cubesatkit_1u-revd-skeleton.jpg7. http://www.cubesatkit.com/content/overview.html8. http://www.cubesatkit.com/docs/cubesatkitsystemchart.pdf9. http://www.cubesatkit.com/docs/datasheet/DS_CSK_MB_710-00484-D.pdf 10. http://gomspace.com/index.php?p=products-bp411. http://www.teledynemicro.com/product/radiation-dosimeter12. https://aero1.honeywell.com/inertsensor/docs/qa3000.pdf13. http://www.crlsensors.com/datasheets/972-V5-H1.pdf 14. http://sensing.honeywell.com/index.php/ci_id/44994/la_id/1/ 15. http://www.stellartech.com/products/techsheets-press/it30XX.pdf16. http://www.makeitfrom.com17. http://batteryuniversity.com/learn/article/whats_the_best_battery