TURKSAT-3USAT: A 3U Communication CubeSat

A. Rustem ASLAN1), Bulent YAGCI2), Ahmet SOFYALI1), Murat SUER1), Ertan UMIT1), Osman CEYLAN2), Bar TOKTAMI1), A. Selim DURNA1), Erdem AKAY1), Iklim G.AKAY1), and I.T.U. NanoSat Group
brahim OZ , enol
3)
1)

GULGONUL3), and TURKSAT NanoSat Group

Faculty of Aeronautics and Astronautics, Istanbul Technical University, Istanbul, Turkey 2) Faculty of Electrics and Electronics, Istanbul Technical University, Istanbul, Turkey 3) TURKSAT Inc., Golbasi, Ankara, Turkey aslanr@itu.edu.tr

As a preliminary effort for Turkeys national aim of designing native communication satellites, TURKSAT Inc. and Istanbul Technical University(I.T.U.) has combined their experience and capabilities to build Turkeys first communication CubeSat, TURKSAT-3USAT. It is a 3U CubeSat, with sufficient room for all the systems with full redundancy. Both in house developed systems based on COTS components and readily available commercial CubeSat systems are used together to achieve redundancy. The payload of the 3USAT is a VHF/UHF transponder to be used for voice communication. The satellite main structure is the ISIS 3-Unit CubeSat structure which is a generic, modular satellite structure based upon the CubeSat standard. As a concurrent study, an in house development of a 3U structure is also carried out. The TURKSAT-3USAT contains two on-board computers; two electric power system, and two beacons and modems along with 10 corresponding antenna. Both batteries and super capacitors are employed to store energy. A de-orbiting system is also designed to de-orbit the satellite following its end of life to comply with the current CubeSat standard and United Nations regulations. Key Words: 3U nano-satellite, CubeSat, Voice communication, Passive attitude control

1.

Introduction

The CubeSats are now considered a disruptive technology revolutionizing the way satellites are built [1]. Most large satellites involve development of custom equipment while CubeSats mostly rely on COTS components due to modest budgets available for their development [2,3,4]. The level of testing is also somewhat reduced since environmental test facilities are expensive and may not be readily available to the developers. The cost and availability of a piggyback launch is currently a major bottleneck, particularly for CubeSat developers from nations without a launch capability. Trksat Inc. Turkeys national communication satellite operator is planning to design and manufacture Turkeys future communication satellites, starting with TURKSAT 5X which will follow TURKSAT 4a and b that are contracted to Japans Mitsubishi Electric Corporation. This is planned to be a joint effort between related national aerospace companies and research establishments including international collaborations. Currently, there are a number of development efforts towards national earth observation satellites. The very first satellite designed and developed locally in Turkey was ITUpSAT1, a CubeSat prepared by I.T.U. [5]. It was successfully placed in its orbit by Indias PSLV -C14 on September 23, 2009. Today, it is still sending its beacon signals which are regularly tracked by many radio amateurs worldwide [6]. Meanwhile, the radio amateur world is also working towards development of small and affordable satellites particularly ones that include a payload which provides a tracking or communication possibility to the radio amateur world. As a preliminary effort for Turkeys national aim of designing native communication satellites, TURKSAT Inc.[7] and ITU has combined their experience and capabilities to

built Turkeys first communication CubeSat, TURKSAT-3USAT. It is a 3U CubeSat, with sufficient room for all the systems with full redundancy. Both in house developed systems based on COTS components and readily available commercial CubeSat systems are used together to achieve redundancy. The payload of the 3USAT is a VHF/UHF transponder to be used for voice communication. The satellite main structure is the ISIS 3-Unit CubeSat structure (www.cubesatshop.com) which is a generic, modular satellite structure based upon the CubeSat standard [8]. As a concurrent study, an in house development of a 3U structure is also carried out. The TURKSAT-3USAT contains two on-board computers; two electric power system, and two beacons and modems. Both batteries and super capacitors are employed to store energy. A de-orbiting system is also developed to de-orbit the satellite following its end of life to comply with the current CubeSat standard and United Nations regulations. The antenna deployment mechanism will be used for payload, modem and beacon antennas. The system of antennas, two dual-antenna and two triple-antenna will be located at each four longitudinal-side surfaces of the structure. Antenna deployment will be ensured by melting wire method. Additionally, a spool like system will be located on the side surfaces of the CubeSat by using antenna holders and pins. The power of each mechanism will be controlled by a micro switch. Documentation is playing a key role in a projects life-cycle. As a quality assurance, the RID (Review Item Discrepancy) forms are created after the PDR and they are being updated by each group after every meeting. These logs enables team to trace of its pace, verify all the steps and result in a more reliable system. TURKSAT-3USAT is planned to be launched by late 2012.

The engineering model of it is scheduled to be ready by January, 2012, including extensive qualification testing to be carried out at related ITU laboratories[6]. 2. Overview of the TURKSAT-3USAT

As illustrated in Fig. 1, TURKSAT-3USAT configuration is composed of modular 1Us. The TURKSAT-3USAT is developed with maximum possible redundancy. All subsystems have a backup system with similar architecture. Where possible, both COTS systems and in-house development are employed. The list of development and COTS subsystems is given in Table 1. The redundant system architecture of the 3USAT is shown in Fig. 2.

placed as most top-position card. Attitude Control Subsystem (ACS) is a passive magnetic attitude stabilization system consisting of a permanent magnet and magnetic hysteresis rods. To provide necessary attitude stabilization and motion damping of TURKSAT 3USAT, ACS must be positioned close to mass and geometry center of the satellite. It should be understood that ACS is required to be in the middle of the satellite and the placement of the ACS is made accordingly. The ISIS3U structure is composed of three separate 1-U structure. The distance between two electronic cards in transition region between the two 1-Unit structure is about 50 mm. The most suitable electronic card for this region is ITU EPS which includes battery and capacitors on it. In addition, the thermal analyses show that the middle unit of the cubesat has no any steep change in environmental temperature. Therefore, both EPS (www.clyde-space.com) cards are identified as top-positioned cards of the first and second units. As a result of the thermal analysis, the transponders are located under the EPS cards to heat the batteries. The Transponders consume 2.7 Watts by having 40% efficiency.

Fig. 1.

The subsystems of TURKSAT-3USAT

Table 1. 3USAT subsystems Develop COTS ment Structure T ISIS3U OBC T Pumpkin ADC T Modem T Astronautical Dev. Beacon T Transponder T TAMSAT Antennae opening T Battery T Clyde Space EPS T Clyde Space Solar Cells 1 panel Clyde Space De Orbiting T Subsystem

The total mass of the 3USAT is about 4kg. The Mass budget is given in Table 2. The interior configuration of 3USAT is determined based on following considerations: Geometric constraints of ISIS 3U(www.cubesatshop.com) , Fig.3. Pumpkin OBC (www.cubesatkit.com) is located as the most bottom card, due to the standard PC/104 stack through connector. Due to camera viewpoint, camera/second beacon card is
2

Fig. 2.

TURKSAT-3USAT system architecture

Table 2. 3USAT mass budget Subsystems Mass (gr) Main Structure 580 ADCS 220 Thermal Control 150 Mechanism 225 EPS 1000 Primary Payloads (Two Transponders) 500 Secondary Payload (Camera) 50 CDHS 295 Communication 450 De-Orbiting 330 Margin 200 Total Mass 4000

4.

Thermal Design

Fig. 3.

ISIS3U structure(in the middle) with ITU developed ones

The thermal management is one of the most critical phases for keeping the subsystems operational in space environment. Prior to the thermal design, thermal systems on cubesats are reviewed and operational temperature ranges of the subsystems are determined, Table 4. As a result a passive thermal protection system was decided because of its light mass, no energy requirements and easy implementation. The passive thermal system on 3U SAT contains Kapton material which covers the outer faces of solar panels, and Mylar films which prevent heat loss. In addition to the passive thermal system, there are heaters on Clyde Space EPS to keep operational temperature of the batteries, between -5oC to 25oC. Following the conceptual design of the thermal system, numerical calculations are performed to predict temperatures of the satellites outer surface and subsystems (Table 5) which are also compared to analytical solution. The results show that, all subsystems but the batteries are in operational temperature range and the heaters on Clyde Space EPS are necessary to keep required temperature values during eclipse periods. This was demonstrated by an analysis for eclipse periods for EPS with heaters on, i.e. the activated heaters are capable to provide the operational temperature for the batteries.
Table 4. Operational temperature range of subsystems Subsystem Operational Temperature Range Main Structure ADCS Batteries Solar Panel EPS CDHS Antenna Transponder OBC De-Orbiting System Camera - 40 oC +85 oC - 30 oC +85 oC -5 oC +25 oC -40 oC +85 oC -40 oC +85 oC - 30 oC +60 oC - 40 oC +85 oC -40 oC +85 oC - 40 oC +85 oC - 70 oC +70 oC -40 oC +85 oC

3.

Structural Analysis

Computational analyses and structural tests of the CubeSat structure are carried out to form a FE Model and to simulate its response to the launch environment. During the structural tests of ISIS 3U, three different cases are taken into consideration to be able to verify the FE models: Case 1: Main panel FEM modal analysis and testing Case 2: Main panels connected by special link elements FEM modal analysis & testing Case 3: Complete ISIS 3U FEM modal analysis & testing The results of modal analyses & tests agree well as shown in Table 3.
Table 3. Comparison of analysis and measurements for ISIS3U 1st Natural Freq. in 1st Nat.ural Freq. in Case Error (%) Modal Analysis Result Modal Testing Result 1 70 Hz 70 Hz 0.00 2 242 Hz 231 Hz 4.76 3 276 Hz 270 Hz 2.22

Table 5. Maximum and minimum temperatures on subsystems Camera & Beacon De-Orbiting ITU Modem Batteries Clyde EPS Transponder 2 ACS ITU OBC ITU EPS Transponder 1 Helium Modem Sensors Pumpkin OBC 20.84 26.68 35.39 42.56 49.74 59.61 43.54 38.87 52.83 62.42 46.70 37.85 33.38 -21.74 -21.34 -20.79 -20.31 -19.83 -19.17 -18.50 -17.51 -15.74 -14.64 -13.68 -12.42 -10.29

Having validated the FE model of ISIS 3U structure, the model extended to include the entire 3USAT subsystems to predict the maximum stresses and natural frequencies (the natural frequencies must be over 100 Hz according to Cubesat Revision 12 Standards). The results showed that the cubesat will not fail under the worst case static loading conditions where the static analysis was carried out for 15 g vertical and 10 g horizontal accelerations as inertial loads. Analysis yield a 60 MPa of maximum stress. Moreover, the first four modes of the 3USAT model were 236.5, 244.6, 248.6, and 251.6 Hz.

5.

Transponder

Transponder is the main payload to provide two way radio communications. TURKSAT 3USAT has 145.940MHz 145.990MHz uplink and 435.200MHz 435.250MHz downlink frequency band. Transponder is the payload of the satellite, furthermore satellite is the first communication satellite which designed in Turkiye. Transponder consists of amplifiers, filters, mixers and AGC (Automatic Gain Control) stages. VHF uplink signal is up-converted to UHF downlink signal linearly. System has 150dB gain with 60dB of the total gain being adjustable. Communication system with transponder has 10 dB link margin. Transponder system specifications are given in Table 6. Transponder consists of three main sub-units: Receiver, gain control and transmitter parts. Receiver part includes a very low noise accorded amplifier and narrow band (50 kHz) image filter. Frequency up-conversion (mixer stage), filter and several gain block, is used to amplify signal power level to -40dBm. Next stage, gain control block includes a variable gain amplifier which adjusts the power between -40 dBm and 5 dBm. Last stage includes a power amplifier which is approximately 50% efficiency with 32dB gain control ability. Consequently, system has 150 dB gain, 1W output power, nearly 35-40% efficiency (Table 6).
Table 6. Transponder system specification Uplink Center Frequency 145.965 MHz Downlink Center Frequency Bandwidth Output Power Receive Sensitivity Gain Total power consumption Automatic Gain Control Antennas PCB sizes Mass Supply Voltage Microcontroller 435.225 MHz 25 kHz 30 dBm (1W) -120 dBm 150 dB <3 W Yes Monopol (Cu-Be) 8.8x8.8x0.5 cm <250gr 2.8V, 3.3V, 5V DC MSP430F5438

Fig. 8.

Transponder desktop model

6.

Antenna System

Satellite communication system includes 3 main devices (sub-systems) with their backups which are modem, transponder and beacon (Table 7). All sub-systems have their own antennas for safety of communication.
Table 7. Subsystems and their antennas UHF Antenna VHF Antenna (435 MHz) Transponder Modem Beacon TOTAL 2 2 2 6 (145 MHz) 2 2 4 4 4 2 10

System

Antennas

The signal is amplified to 1W before transmitting and this blocks gain is controlled by automatic gain control system to fix the output power to 1W (30 dBm) to keep power consumption stable. Additionally, gain control unit protects power amplifier input and output power can be changed from ground station remotely. The signal is amplified to 1W before transmitting and this blocks gain is controlled by automatic gain control system to fix the output power to 1W (30 dBm) to keep power consumption stable. Additionally, gain control unit protects power amplifier input and output power can be changed from ground station remotely. On a desktop model electrical and radio properties were tested (Fig. 8). Engineering model design process continues on a single board sized 88x88mm which is defined in satellite structural layout.

145 MHz and 435 MHz monopole antennas thickness and width are determined as 0.3 mm and 3.6 mm by using Ansoft HFSS software tool. Theoretically, monopole /4 antenna length for 145 MHz (VHF) is 574 mm. This length is very long so this may cause problems on satellite surface for placing antennas and deployment system. Durability of the antennas would be a problem because of this length. Otherwise, it is impossible to locate 10 antennas without any collision and magnetic interference at each surface. Furthermore, long antenna structure complicates the deployment by a wire-melting system. Therefore, 145 MHz /8 monopole antenna designed. As a result, /8 monopole antenna does not have 50 impedance (Z = 40.6 j251.9), thus an impedance matching network is necessary to deliver maximum power. Female 50 MMCX connector is used in this project between the devices and antennas. MMCX connector and connection points to hold antenna stable on the surface of the satellite are modelled by using Ansoft HFSS simulation tool considering the actual structure characteristics. Electromagnetic simulations are used to obtain best efficiency for 10 antennas to find locations on the satellite taking into account mechanical constraints. Two surfaces on the satellite are reserved for antennas. 8. Electric Power System

TURKSAT-3USAT have two redundant EPSs. The main unit is 3U EPS from Clyde Space. Main EPS has 3 MPPT charge controller one for each axis. Energy is stored using Li-Polymer batteries in 2 series configuration. Batteries have a heating system for cold eclipses. Main EPS provide power bus 3.3V and 5V regulated voltage and a floating battery voltage. The secondary system is being developed in ITU. It also has 3 MPPT controllers with perturb and observe algorithm. Energy is stored in Supercapacitors. Supercapacitors provide less Wh per kg, but they have much longer lifetime and temperature characteristics. Two lithium polymer
4

supercapacitors have implemented in series configuration to store energy during eclipse. Standard operating voltage is between 2.2V and 3.8V for the chosen supercapacitor [9]. Therefore stored energy will be = 2,3 Wh. Table 8 shows that required energy for the worst case is about 2 Whr, therefore the storage can supply the entire system even for the worst case. The operating temperature is from -25oC to 60oC, which is within the limits of thermal simulation results, therefore no heating or cooling system is required. A demonstration model is built and tested for the developed EPS system, Fig.12. It is tested with regular ground use silicon based solar panels. It was seen that MPPT charge and regulators work without any observed problem.
Table 8. Energy Requirement (worst case) Transponder OBC Beacon Attitude Det. Modem TOTAL Power budget requirements Power Time (W) 2,8 0,1 0,5 0,3 1 (min) 35 35 15 5 10 Energy (Whr) 1,6333 0,0583 0,125 0,025 0,1666 2,008

10.

Attitude Determination and Control System

Fig. 12. Demonstration of developed EPS

Solar panels will be provided mostly by Clyde Space. One of the solar panels will be produced in ITU. A quick demonstration panel is built from a 2 sided PCB. There will be temperature sensors and reverse protection diodes on the solar panel. Two Solar panels are attached on panel. Later on, the cells will be covered with a cover glass from Qioptiq [10]. Due to our previous experience with solar simulators, a LED based solar simulator is tested. A 100W LED with reflectors and optics is used to light the cells. The cell short circuit current was 430mA, which should be about 500mA in orbit. The LED solution does not provide enough radiation to simulate orbital sun energy, but after 2 min of illumination the panels does not show too much warming, which is good for long term testing. 9. Camera

The mission has no precise pointing requirement, thus the satellite will be controlled passively by onboard magnetic moment production. Snce no active control will be employed, no onboard attitude estimation is required. Therefore, angular motion will be only sensed by the 9 degrees of freedom sensor unit of the satellite, and the transferred measurement data will be processed on ground to determine the attitude states corresponding to angular motion measurement sets. The components of such a passive control system are permanent magnets and hysteresis rods. Permanent magnets that pass through geomagnetic field in orbit produce a magnetic restoring torque that is proportional to their total magnetic dipole moment value. Differently, hysteresis rods produce a damping torque thanks to the energy dissipation property of soft ferromagnetic materials. In other words, permanent magnets, which are hard ferromagnetic materials, exchange the angular momentum of the satellite while hysteresis rods reduce it by converting a part of the kinetic energy of the angular motion to heat and consequently reducing the angular velocity. The restoring torque counteracts the components of the environmental disturbance torques, Td, that increases the angle between the magnet dipole moment (mpm) vector and the geomagnetic field vector, B. If that angle is symbolized by then; mpm = Td/(Bminexp) can be written, where Bmin is the minimum magnitude of Earths magnetic field encountered in orbit and exp is the minimum expected value of [ 11]. If the disturbance torques emerging from aerodynamic drag, gravity gradient and solar radiation pressure are simulated for Sun-synchronous, circular orbits with altitudes of 600 and 800 km by using realistic mathematical models that take the momentary attitude state of the satellite into account. The necessary mpm values are given in Table 9.
Table 9. altitude [km] Td [N/m] exp [deg] 20 10 5 Necessary dipole moment onboard 600 800 8.806x10-8 5.595x10-8 mpm [Am] 9.223x10-3 1.817x10 3.619x10
-2 -2

9.107x10-3 1.794x10-2 3.574x10-2

C329 UART camera module is chosen, due to its size, power consumption and simplicity. The resolution is VGA and the output is JPEG picture format. On the structure, Fig. 3., a hole is put to stick the lens of the camera module. Position of the top layer is adjusted for the camera module. An UART interface is implemented to control the camera and pass the picture information to OBC or Modem.
5

Due to the restricted volume for the attitude control card in the designed satellite, the magnets onboard are not allowed to have elongation such as four or five, which are typical minimum values for available AlNiCo-5 magnets.Thus AlNiCo-8 magnets are chosen, which can be manufactured with elongation values of two or less thanks to their higher coercivity, the resistance to demagnetization. If magnets of AlNiCo-8 with diameter of 6.35 mm and height of 9.53 mm are preferred then the number necessary to reach the maximum mpm value in Table 9, which is 3.619x10-2 Am, is calculated to be 2.08x10-1. Every satellite has a residual magnetic dipole moment value that emerges from inductions in electrical circuits onboard. It is complicated to estimate its value therefore it will be taken into account as a disturbance component. To counteract the undesired torques due to the residual magnetic moment,

unpredictable changes in space environment, and possible collisions with debris that are not fatal, the calculated necessary magnet amount should be multiplied by a safety factor. In Ref [11], that factor is taken as 30 for the microsatellite UNISAT-4. For 3USAT, a factor of 16 is acceptable, which corresponds to the usage of 8 magnets. The selected safety factor has to be judged through simulations to decide on its ultimate value. For an analytically sophisticated decision, the resonance issue between the natural frequencies of the satellite and the frequencies of perturbations arising from non-uniform rotation of the local geomagnetic field vector due to the satellites orbital motion has to be investigated [12,13,14,15]. The damping magnetic moment is produced by hysteresis rods according to the relations; k = tan[(0.5Mr/Ms)/Hc] M=(2Ms/)tan-1[k(HHc)] mhys = MnV where H is the magnetic field strength along the axis of the hysteresis rod, M, Hc, Mr, and Ms are respectively the magnetization, the coercivity, the remanence, and the saturation magnetization of the rod, k and V are respectively the dimensionless form factor and volume of the rod, and n and m are respectively the number of rods and the induced magnetic dipole moment along each principal axis [16]. Since the characteristic values Hc, Mr, and Ms that determine the hysteresis cycle of the rod differ from the catalogue values for HyMu80, which is the material of the manufactured rods and is an Iron-Nickel-Molybdenum alloy with 80% Nickel composition, the actual values of these three parameters have to be found. If the rod is put into a solenoid and a magnetic field is created inside the solenoid, the magnetization characteristics of the specimen can be measured by observing the inducted voltage in a second coil around the solenoid according to the Newman-Faraday-Lenz induction law, which says that an alternating current passing through the solenoid induces an electromotor force along the induction (second) coil. As the result of the hysteresis tests on the developed test stand, the measured values of the ferromagnetic parameters are Hc = 52.13 A/m, Mr = 0.022 T, and Ms = 0.0578 T. Restricted by the available space and inspired by previous missions, it is planned to place three hysteresis rods on each of the rod axes. The layout of the components of the passive magnetic attitude control system on the PCB should match the following criteria for the best performance [17]: Hysteresis rods are to be placed in the plane perpendicular to the permanent magnet dipole axis in order to obtain damping torque as required. Hysteresis rods are to be placed orthogonally to each other to obtain the best performance. If the hysteresis rods are in the equatorial plane of the magnets then there is theoretically no interaction between magnets and rods even if they are in close proximity. The parallel distances between the hysteresis rods have to be at least 0.3 times their length so that they can act individually.

9.

Conclusions

A nano-satellite with full redundancy is developed for voice communication at low earth orbit. It can be considered as a preliminary effort for Turkeys national aim of designing native communication satellites considering Turkish national satellite operator TURKSATs plan to produce the first GEO communication satellite in 2015. The present study will present what can be achieved with the developed systems for the communication performance. Acknowledgments The project is fully supported by TURKSAT Inc. of Turkey. Contributions of Hasan Krk and Kenan Yce Sanliturk to the structure development are gratefully acknowledged. References
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