Conceptual design review

Project: Aeolus satellite structure

Engineering team:
Raja Guru
Suresh Muthaiah
Sundarvathanan
Rakesh Gunasekear



Design Objective


Cube sat
Need CTQ
Technical
cost
Structural integrity
Mass
Availability
Carry sub systems
Low cost

Compatibility
Low density

Manufacturing
time
VOC
Driving parameters
From the customer through VOC following are the needs identified;

Performance
Low cost
Compatibility
Reliability
Low density
Availability
Above mentioned are the identified requirements from the customers for
this review.




Challenges, solutions and advantages

Challenges:
Shorter working life
Less pay loads
Power constraints
Lower transmitter output
capacity
Redundancy only for critical
systems
Rapid orbital decay


Solution:
Advancement in
small satellite
technology!!
Advantages of solutions:
Rapid expansion of
technology
Diverse potential users since
we could achieve various
mission agendas
More frequent missions
Opportunities for research
activities

1U satellite requirements
Operational requirements
Accommodate payload
systems for LEO missions
Able to accommodate as a
piggy back option.
Capable of operating in
LEO orbits
Ability to withstand loads
during various mission
phase.
Accommodate all
deployable for LEO missions
Accommodate sub systems
for LEO missions(as per
mission)



Performance requirements
Holds the payload as an
integral unit
Satisfy the PSLV interface
design requirements
Capable to transmit
required communication
Withstand launch loads,
thermal loads, perturbations,
and yet flexible
Accommodate booms,
antennas, solar panels
Accommodate sub systems
as given by the cube sate
design specification

Payload systems & applications
Scientific research
Technology demonstration
Earth observation
Telecommunications
Low cost launchers
Military applications
Academic training

Design Concepts
Materials

Stainless steel
Titanium
Alumininim
Composites
Inconel

Interface
Plate with hole
Plate
Isogrid
Column



Design configuration
Size 100mm ( 0.1mm)
Height 113.5mm (0.1mm)
Stacked, slots
Mass 1.33 kg (dry)


As per cube satellite design
specification





Final Proposed Concept:

Aluminum 6061 : High strength, light-weight, easy machinability, and cost
Isogrid: Low mass and high strength
Size 100mm ( 0.1mm), Height 113.5mm (0.1mm)
Structural Mass: < 400 grams
AL-6061-T6 320 MPa 2850 kg/m3 Easy $15.00
AL-7075-T6 340 MPa 2796 kg/m3 Easy $30.38
Structure configuration
Competitors
Cubesat shop
Clyde space
Cubesat kit
ISIS
Gomspace
Stras space

Name
Space
proven Dry mass(grams) thermal range C Material
Cube satkit P 300 (-) 40 to 85 degree Alumininium
ISIS P <400 (-) 50 to 90 degree Alumininium
Clydespace P 300 (-) 40 to 85 degree Alumininium
Gomspace P 725 Alumininium
Gantt chart
Gantt chart Feb March April May June

Design study
Conceptual design review
Preliminary design review
Critical design review
Final design approval
Procurement
Proto type manufacturing
validation and testing



Conceptual design diagram
Launch vehicle constraints Functional requirements
Structural configuration
.
Preliminary structural design
Natural frequency
constraints

Structural analysis
Stress
Thermal
Dynamic
FEM

Fabricate structure
Testing
Temperature distribution
Spacecraft dynamic
model
Coupled load analysis
Dynamic response(iterative)
Preliminary launch loads
Thermal analysis
Budget
Direct cost
Estimated period
Salary
Specific material
Transport
Sub contract
Indirect cost
Employee benefits
Office rent
Equipements
Analysis tools
Administrative cost
Cost estimate







Input considered:

Activity cost estimates
Project schedule
Resource availability











Output:
Cost performance
Funding requirements






Budget
*Project schedule 6 months
Engineering members 4

Direct cost INR
Engineer salary 400000
Material ( 2mm sheet) 2000
Transport 10000
Subcontract(40%) 800000
Indirect cost INR
Office rent(6 months) 100000
Equipments 100000
Analysis tools 2000000
Administrative cost 20000
Employee benefits(5%)10000 20000
Total 3452000





Output:
Approximate budget to design and
manufacture cube satellite bus (
with 10% extra) would be 38,00,000
INR.
Fund required for ISRO validation,
testing after 4 months from kick off








Risk and contingencies plan


Risk

Likelihood Impact Risk Management Approach/Prevention

Illness

Med

High

Seek Medical Adviser . Consult with the supervisor if becomes
more serious

Lack of MSC Patron skills &
Knowledge at initial stages

Med

Med

More background reading. Also Seek advice from the expert
Lack of knowledge of
Vibration analysis. And
Launch load analysis
High

High Read up on previous examples or on similar techniques.
Require Experience stress Engineer And Also Seek advice from
the expert.

Lack of knowledge of thermal
analysis and space thermal
environment

High High Read up on previous examples or on similar techniques ,
software training (MSC software /NX ) ,and Seek advice from the
ISRO expert
External changes to the
project

High High Continuous meetings with ISRO scientist (Advice) and all the other
groups working on the project to ensure any changes are anticipated
and dealt with in sufficient time

Changes to the CubeSat
design

High

Med

Tie in with Cube Sat design team to ensure that the Design change

Workshop & Manufacturing
Delays

High

High Try to submit the drawing as early as possible .Identify alternative
manufacturing facilities.
Malfunctioning of the Cube
sat system

Med High Verify the design concept & check the final drawing with design
validation team and Workshop Technicians prior to submission

Loss of Data

Low High Ensure a proper backing-up strategy is in place. Trying to back up
in various places the University file store, and Online

Experimental Testing Delays High High Identify alternative Testing facilities.