Integrated System Build & Test with Customer Demo
Table of Contents
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Team Vision for System Level Demo with Customer
- Finish Fabrication
- Integrate Ultem Parts Succeeded!
- Rebuild Rails Succeeded!
- Rebuild system as necessary Succeeded!
- Fit Test II Succeeded!
- Full System Creep
- Time to Remove
- Finish ImagineRIT Succeeded!
- Order backup parts Succeeded!
- Reorder Ultem as necessary Succeeded!
Product IThis phase, we have our first product to incorporate Ultem structure, aluminum rails, a mass analog and all wiring. We call this iteration Product I. All of the testing and analysis for this phase is made using Product I.
Ultem PrintingThis phase, we received the printed Ultem parts we ordered from Stratasys. Due to a miscommunication, Stratasys printed an older revision of our design instead of the most recent one we went them. The fidelity on these prints is extremely good. Holes and wire paths do not not have the kind of deformation we saw with ABS.
Mass AnalogTo mimic the presence of internals during vibration tests, a mass analog is used. We have made a revised mass analog for this phase. The mass analog has a 3-D printed ABS structure with steel rods inserted for added mass. The target mass for the analog is 930g. As shown in the image below, the actual mass created is 935g, which walls within the acceptable range. We believe that this mass analog will accurately represent the presence of internals during testing.
Table Top Deploy IIITo test the reliability of the solar panels to deploy, a table top deployment test was run.
Video of TestTable Top Deploy with Ultem
ResultsDuring the test, one and only one of the panels deployed. The second panel did not deploy because the restraining line on that side never melted all of the way through and the old wire routing pinched the line, not allowing it to go slack from the other side being cut. We also noticed some interference between the hot plate standoffs and the deployable backer panels.
TakeawaysThe outdated design caused exactly the same problems that lead us to change them in prior iterations. We believe that once we have the most recent design printed out of Ultem, deployment will be successful. We will also adjust the positioning of the NiChrome wire so that it has better contact with the restraining line, facilitating melting.
Fit Test II
- From last phase it was determined that being slightly oversized on the square rail to rail dimension was best.
- From the table above all dimension meet the standard or are slightly larger so that slight machining can be done to bring the dimensions within spec.
High Altitude Balloon
Test PlanWith this opportunity, we'll ride on the side of the HAB II Launch (April 22nd target date) to test the thermal characteristics and low pressure deploy of the cubesat frame design. The balloon will ascend to 60,000 to 100,000 feet, run both hot knifes wired in parallel for ten seconds and deploy the arrays. A camera will be trained on the vehicle for the duration
Temperature Regime: -56 to -45 degrees Celsius (-70 to -50 degrees Fahrenheit) Pressure Regime: Approximately 1/10th of Surface (1.692 lb/in2 versus 17.554 lb/in2)
- Time delay on deployment will indicate power requirement with decreasing temperature and decreasing convection
- Deployment video will show failure modes after a long flight
- Creep testing through hot middle atmosphere
- Flight similar conditions
- Validation for launch, operations, and command processes
Risk and Problem Tracking
With the arrival of Ultem from Stratasys, we are confident that we will not require RIT to print Ultem for our project this semester. Because of this, we can remove RIT's ability to print Ultem from our risks.
The arrival of the Ultem parts closes two problems but creates another. We have shown that we can obtain Ultem so problems around ordering and printing it are over. However, the Ultem parts sent to us were from the wrong design revision and do not reflect the most recent changes. This represents a new major problem for us.
Bill of MaterialsThis phase we ordered components for the deployment switch and for analog solar panels. These orderes are reflected on the new BOM. Also reflected is the arrival of printed Ultem from Stratasys.
|ER and Description||Minimum||Ideal||Current||Status?|
|1 Min Undeployed Area Time (cm2-orbit)||100||100||100||SATISFIED|
|2 Deployed Area Time (cm2-orbit)||150||300||300||SATISFIED|
|3 System Mass (grams)||420||300||180 (460 with solar panels)||SATISFIED|
|4 CubeSat Clearance (mm)||1||1||>1||SATISFIED|
|5 Time from Command (s)||2<t<8||2<t<8||~ 7||SATISFIED|
|6 Operating Temperature (deg C)||(-40,40)||(0,20)||?||?|
|7 Available Interior (mm)||96 90 85||100 100 100||Pumpkin CubeSat PCB Standards||SATISFIED|
|8 Exterior Protrusion Space (mm)||6.5/face||6.5/face||6.5 two faces, 4, two faces||SATISFIED|
|9 Change in COM (mm)||50||>10||>1||SATISFIED-Simulation|
|10 Constant Launch Acceleration (g)||6||8||6-survived||SATISFIED-Simulation|
|11 Cost of Prototype ($USD)||500||400||$500||SATISFIED|
|12 Time to Remove Blank (s)||8||6||?||?|
|13 Launch Vibration Test (Pass/fail)||Pass||Pass||SATISFIED-Simulation|
|14 Full Documentation||Pass||Pass||Pass||SATISFIED|
Imagine RIT PosterBelow is the most up to date version of the poster we will present at Imagine RIT. As we complete the remaining tests and builds, the rest of hte poster will fill in.
Technical PaperWe have begun work on our final technical paper. We are approximately 50% of the way into the writing of the paper. We believe we are on track to meet the 75% by 4/21 deadline.
Plans for next phase
- Full System Creep - Tristan, Rob
- High Altitude Balloon Test - Anthony, Paul
- Time to Remove - Anthony
- P16103 - Full team
- Thermal Testing - Rob, Paul
- ImagineRIT - Tristan, Anthony
- Submit to the Journal of Small Satellites - Anthony
- Finish SPEX Closeout - Full team
- Present to SPEX Group - Full team
- Re Re Re Order Ultem for Final Build - Paul