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