Jake Broadway 1 I&T.900.

0 ALL-STAR Exo-Panel Integration

ALL STAR Space Segment Assembly Procedure ALL STAR-SYS.500.0 DRAFT

Revision DRAFT

Date 11/15/2012

Authored By Jake Broadway

Description Draft Release

Document Approvals

Originator: Colin Towery

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Project Manager: Jesse Ellison Integration Approvals

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QA representative:

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Systems Engineer: Colin Towery

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Subsystem Lead:

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Project Manager: Jesse Ellison

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Mentor: Brian Sanders

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Jake Broadway 2 I&T.900.0 ALL-STAR Exo-Panel Integration

Table of Contents

Jake Broadway 3 I&T.900.0 ALL-STAR Exo-Panel Integration 1. Authors Contact Information Jake Broadway Structures, Integration and testing jacob.broadway@colorado.edu 303-525-9148 2. Introduction 1.1 Integration Purpose and Objectives This document will outline the integration procedure for the Exo-Panel Assembly of the ALL-STAR CubeSat. This is intended to be a subsection of the full integration document. This is a procedure that can be followed as part of the full integration procedure, or an independent one to be used to reintegrate the Exo-Panel Assembly.

Figure 1: ALL-STAR 3U CubeSat Assembly Highlight

Jake Broadway 4 I&T.900.0 ALL-STAR Exo-Panel Integration 1.2 Applicable Requirements The Result of this integration will fulfill the following Requirements of the subsystem. Requirement Description Number <req1> Mass of Structure shall be ________ Shall fit in _____ dimensions with an accuracy of ___ Verification Method Inspection Inspection

1.5 Acronyms Acronym Definition ICD Interface Control Document ALL-STAR Agile Low-cost Laboratory for Space Technology Acceleration and Research SYS Systems STR Structure PEZ Payload Extension Zone EPS Electrical Power system 3. Quality Assurance (QA) Precautions During any part integration there shall be a Quality Assurance person present to verify the work of the team member performing the integration. 2.1 Pass/Fail and Re-Test Criteria Depending on the sub-system being operated on, the assembly must be integrated to pre-determined standards decided by the reason for integration: i.e. vibration testing, day-in-the-life testing, or flight readiness. The required quality of integration must be decided before the integration procedure can begin and will be determined by the Integration and Testing team, the team lead of the sub-system(s) involved, and the Program Manager. In order to pass this integration procedure, the assembly must fulfill all requirements of the system listed in section 1.2. 2.2 Quality Assurance A Quality Assurance representative shall perform the following functions: Verification of the integration procedure and facilities that must be utilized Step-by-step verification of the accuracy and quality of the system integration. Documentation and verification of changes that must be made to integration process due to unforeseen hindrances. This documentation will be written at the end of this full integration procedure.

Jake Broadway 5 I&T.900.0 ALL-STAR Exo-Panel Integration

Jake Broadway 6 I&T.900.0 ALL-STAR Exo-Panel Integration 3. Test Resources 3.1 Facilities Anteroom Static mats Integration Lab 3.2 Equipment <Record and identify equipment used. This way, if the equipment is faulty and not the projects hardware, the faulty equipment can be identified.> Tools 1. 5/64 in Allen Wrench 2. 3/32 in Allen Wrench 3. Torque wrench (goes down to 4 in-lb) 4. Digital Calipers 5. Thread Lock (kind unknown yet) 6. Digital Camera 7. Isopropyl Alcohol 8. Tooth Brush 9. Digital scale 10. Integration Jig 11. 7/32 Allen Wrench 3.3 Components Components 1. 2. 3. 4. 5. 6. 7. Exo-Panel A Exo-Panel B Deployment Spring Deployment Spring Mount 2-56 5/16 inch bolt 4-40 0.1875 inch bolt 2-56 5/32 inch bolt Quantity 1 1 2 1 1 1 1 1 Clean Initial Clean Date

Quantity 2 2 2 2 2 12 2

Clean Initial

Clean Date

3.3 Cleanliness / ESD Controls Determined prior to start of integration by quality assurance and involved team members based off of system being integrative and reason for integration.

Jake Broadway 7 I&T.900.0 ALL-STAR Exo-Panel Integration

4. Exo-Panel Integration Procedure 4.1 Pre-Integration Procedure

1. Pre-Integration Procedure Pre-Integration Meeting, All team Members will gather and review the Procedure. Each team member will be clear about their responsibilities. This will include a dissuasion of work space, cautions, warnings and Communication protocols. Integration Engineer #1 ____ Quality Engineer ____ Establish a clean work space as determined in Section 1. Pre-Integration Procedure. Static precautions in place Clean, grounded static mat. Team members in Clean Room Attire ****************************************************** Caution : When Gathering components do NOT remove from Static protection measures ****************************************************** Gather and organize necessary equipment listed in section 3.2 and 3.3. This document will indicate parts used during each phase of integration so not all of the listed parts need to be in the workspace but should be readily accessible during the integration process. Verify that each critical component is a flight ready component 1) 2* Exo-Panel A Completed and signed off _____ 2) 2*Exo-Panel B Completed and signed off _____ 3) 2*Deployment Spring Completed and signed off _____ 4) 2*Deployment Spring Mount Completed and signed off _____ Initial Date

2.

3.

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5.

QA ________________

QA ________________

QA ________________

QA ________________

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5) Bus Assembly Completed and signed off _____ QA ________________ Ensure that quality assurance and personnel required to be present are present.

Jake Broadway 8 I&T.900.0 ALL-STAR Exo-Panel Integration Quality Engineer ____

Jake Broadway 9 I&T.900.0 ALL-STAR Exo-Panel Integration

4.2 Integration Deployment Spring Assemblies

Integration Structure Deployment Spring Assemblies
1. Components necessary for Battery Structure Side 1

Initial

Date

1. 2 * Deployment Spring 2. 2 * Deployment Spring Holder 3. 2 * 2-56 5/16 inch bolts Deployment Spring Deployment Spring Mount

2-56 5/16 inch Bolt

2.

Insert deployment spring mount into deployment spring. Insert 2-56 5/16 inch bolt into deployment spring holder.

Jake Broadway 10 I&T.900.0 ALL-STAR Exo-Panel Integration Integration Structure Deployment Spring Assemblies Bolt 2-56 5/16 inch bolt to PEZ panel structure at one of the interior corners without a locking plunger. Tighten to hand tight. With the end of the spring oriented towards the exterior of the structure, the spring should point towards the front of the PEZ panel structure. Initial Date

3.

Location of deployment spring bolt hole

Jake Broadway 11 I&T.900.0 ALL-STAR Exo-Panel Integration Initial Integration Structure Deployment Spring Assemblies Repeat steps 1-2 to form another bolt-holder-spring assembly. This should then be bolted to the PEZ panel structure at the corner opposite that of the previous spring. This corner should also not have a locking plunger. Date

4.

Jake Broadway 12 I&T.900.0 ALL-STAR Exo-Panel Integration

4.3 Integration Exo-Panel Structure

Integration Exo-Panel Structure
1. Gather components necessary for Exo-Panel Structure Side 2

Initial

Date

1) 2 * Exo-Panel A 2) 2 * Exo-Panel B 3) 2 * 2-56 5/32 inch bolts 4) 12 * 4-40 .1875 inch Bolts Exo-Panel A Exo-Panel B

Note extra extrusion and bolt hole

Jake Broadway 13 I&T.900.0 ALL-STAR Exo-Panel Integration Initial Integration Exo-Panel Structure Align the three prongs from Exo-Panel B into corresponding indentations along the rail of Exo-Panel A. Bolt using 4-40 .1875 inch bolts. Tighten to hand tightness. All backboard fingers should be on the same side. Date

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3.

4.

*********************************************************** Caution: during the following step care should be taken to minimize contact with the solar panels on the bus structure. When the Exo-Panels are placed upon the sliding rails on the bus structure, they should not contact any part other than the sliding rails *********************************************************** ***************************************************** Caution: At all points during steps 3 and 4 the attached Exo-Panels are loose from the PEZ structure and it is required to hold them in place by hand. They may only be released upon the completion of step 4. ********************************************************

Jake Broadway 14 I&T.900.0 ALL-STAR Exo-Panel Integration Integration Exo-Panel Structure Align the Exo-Panels discussed in the previous step such that the extra extrusion in Ex-Panel A is directly above one of the deployment springs. The side of Exo-Panel A with the extra extrusion should be the portion of the Exo-Panel closest to the PEZ structure. Pull the end of the deployment spring to the bolt hole in the extra extrusion in ExoPanel A, without twisting the spring, such that the bolt hole in ExoPanel A and hole in the deployment spring align. Bolt deployment spring to Exo-Panel A with a 2-56 5/32 inch bolt. Initial Date

5.

These are the two holes to be aligned (Spring to Exo-Panel).

Jake Broadway 15 I&T.900.0 ALL-STAR Exo-Panel Integration Initial Integration Exo-Panel Structure Securely place the Exo-Panels approximately halfway up the sliders on the PEZ structure. Slowly allow the deployment spring to pull the ExoPanels towards the rear of the PEZ structure while keeping the Exo-Panels firmly along the sliding rails until the locking plungers lock the ExoPanels in place. Rotate the assembly on the integration jig until the ExoPanels are on the bottom. While rotating the integration jig, keep the portion of the Exo-Panels resting on the bus structure firmly gripped so that they do not fall off. Only at this point may the Exo-Panels be released and remain in place on the PEZ structure. Date

6.

Jake Broadway 16 I&T.900.0 ALL-STAR Exo-Panel Integration Integration Exo-Panel Structure Align the indentations in the remaining Exo-Panel B to the prongs in ExoPanel A. Thread the bolt holes using 4-40 .1875 inch bolts. Tighten to hand tight. Rotate on the jig until the attached Exo-Panel A is in the bottom-most position. Initial Date

7.

Jake Broadway 17 I&T.900.0 ALL-STAR Exo-Panel Integration Integration Exo-Panel Structure Align the remaining Exo-Panel A to directly above the remaining deployment spring with the extra extrusion towards the front of the PEZ panel structure. Pull the end of the deployment spring towards Exo-Panel A and align the bolt hole in the extra extrusion and the hole in the end of the deployment spring. Thread with a 2-56 5/32 inch bolt. Tighten to hand tight. Initial Date

8.

Jake Broadway 18 I&T.900.0 ALL-STAR Exo-Panel Integration Integration Exo-Panel Structure Align the Exo-Panel A in the previous step so that the indentations fit together with the corresponding prongs from the Exo-Panel B on the side of the Exo-Panel A with the indentions, and so that the prongs on ExoPanel A fit into the corresponding indentations on the Exo-Panel B on the side of the Exo-Panel A with the prongs. Thread all six holes with a 4-40 .1875 inch bolt. Tighten to hand tight. Initial Date

9.

Verify the Final Structure Integration Engineer ______ QA _______ Subsystem Lead _______________ 1. Take Pictures of Structure. Makes sure to take both sides.