Spacecraft Mechanical Sub-system

Design & Manufacturing

Introductory Course
Presented by
Atipat Wattanuntachai | atipat@gistda.or.th

1
Acronyms
S/C = Spacecraft CAD = Computer Aided Design
L/V = Launch Vehicle CAM = Computer Aided Manufacturing
AIT = Assembly, Integration and Test CAE = Computer Aided Engineering (Analysis)
EVT = Environment Test DR = Discrepancy Report
AOCS = Attitude and Orbit Control Systems
RF = Radio Frequency
MGSE = Mechanical Ground Support Equipment
CoG = Center of Gravity
FEM = Finite Element Modelling
FEA = Finite Element Analysis

2
Contents
▪ Mechanical Sub-system Introduction
– Mechanical Engineering
– Launch Vehicles
– Satellite
– Class of Satellite (by application & by mass)
– Satellite Platform & Payload
– Satellite Structure Feature
– Satellite Structure Classification
– Satellite Structure Architecture

3
Contents - Cont.
▪ Mechanical Design & Manufacturing
- Requirement Gathering
- Design Consideration
- Derived Requirement
- Heritage Design
- Platform Selection
- Project Lead-time
- V-Diagram
▪ Procurement
▪ Inspection
- Mechanical Engineer Roles
- How to Start Designing
- Design & Manufacturing Tools
- Material Selection
- Manufacturing Technique
- Design for Manufacturing
- Worth Mentioning Concept
4
Mechanical Engineering: ME
“Mechanical engineering is an engineering branch that combines engineering
physics and mathematics principles with materials science to design, analyze, manufacture,
and maintain mechanical systems. It is one of the oldest and broadest of the engineering
branches..” - Wikipedia

“Mechanical Engineering takes in all built structures and moving parts flown in space,
which includes automation and robotics, instruments for scientific missions as well as
assessing the effects of the space environment on materials.” - The European Space
Agency

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Launch Vehicles

THEOS-2 SmallSAT Launcher

(Auxiliary payload)

6
Launch Cost

7
Class of Satellite (by Mass)

Credit: https://www.nanosats.eu/cubesat Credit: Canadian Space Agency

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Spacecraft Structure Features
Primary Features
✔ Accommodate payload, instruments, and compulsory on-board avionics
✔ Provide a mechanical interface between spacecraft & launcher
✔ Provide a sufficient stiffness to meet a natural frequency requirement of launcher and to minimize a
dynamic amplification between launcher & satellite by carefully performing a modal design
✔ Provide a capability of S/C to withstand a launch environment (vibrations, high G-force, and shock
event)
✔ Provide a sufficient mechanical stability to satisfy a pointing sensitive payload requirements i.e.
build tolerance, alignment, micro-vibration, and thermo-elastic stability)
To make sure the S/C will get into orbit in one piece!

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Spacecraft Structure Features (Cont.)
Secondary Features
✔ Protect payloads & avionics from harsh environment in outer-space (cosmic radiation & temperature
fluctuation in orbit)
✔ Protect payloads & avionics component from depressurization during launch and vacuum
environment in space
✔ Provide a proper electrical grounding design for electronic and power equipment
✔ Provide mechanical ground support equipment (MGSE) interface and harness routing accessibility to
accommodate AIT needs
✔ Provide an optimum assembly pattern to satisfy AIT requirement

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 Spacecraft Structure Classification
Primary Structure
- Carries a majority of mechanical loading
during launch
- Know as “load path structure” that
transmits loads from launcher interface to
the rest of S/C
SMART-1 S/C Primary Structure
- Any failure of this structure can cause the Credit: sci.esa.int/web/smart-1
S/C to collapse which means a major loss
of mission functionality
- i.e. separation ring, centre tube, thrust
tube, separation panel, struts (all fixing JUICE S/C Primary Structure
Credit: sci.esa.int/web/juice
element)
ESTCube-1 Cubesat
Credit: https://en.wikipedia.org/ 11
 Spacecraft Structure Classification (Cont.)
Secondary Structure:
- Carry a significant mechanical loading
- This structure accommodate most of equipment
inside/outside S/C
- Any failure of this structure can cause a partial loss of S/C
mission functionality
- i.e. closure panels, deployable panel & hinges
Credit: Mohamed A., Cairo University, Egypt
Tertiary Structure / Non-Structural Mass:
- Any component which does not carry a significant load within the
structure or contribute to structural behavior / performance
- i.e. small equipment, avionic modules, brackets
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 System
Requirement

Requirement Gathering Assembly,

Integration
, and Test
Payload

Mechanical
Radio Launch
Frequency
Derived vehicle
Requirement

Space
Power
Environment
THEOS (Thaichote) Attitude
and Orbit
Control
Systems
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Design Consideration

Derived Heritage
requirement design

Platform Project lead

selection time

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Derived Requirement
• Can use any tools
• QFD matrix is one of the best choices
(also known as House of Quality)

Customer Requirement
(Mission objectives)

System Level
Requirement

Sub - system Level

Requirement 15
 Heritage Design THEOS-2 SmallSAT: Launch expected 2022

✔ Space proven
✔ Lower development time
✔ Lower risk of schedule delay
✔ Faster integration and test (similar configuration)
✔ Economic of scale (i.e. same size module box, MGSE)
✔ Lower EVT requirement (Test only to acceptance level)

CARBONITE-1: Launched 2015 CARBONITE-2: Launched 2018

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Platform Selection SSTL-CUBE 8U-12U CUBE SAT

✔ Lower development time (if not develop new platform)

✔ Faster integration and test (similar configuration)
✔ Economic of scale
✔ Lower EVT requirement (May not need to test for 50-150 KG
SSTL-MICRO
constellations) THEOS2 SMALL-SAT

SSTL- 200 KG OR
MINI MORE

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Class of Satellite (by Application)

Communication & Relay Earth Observation Scientific

(Thaicom 4) (THEOS-2 SmallSat) (Hubble Space Telescope)

Meteorological
(Himawari)
Reconnaissance Navigation
(TacSat-4) (Galileo, GPS, Beidu, GLONASS)
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 Frame-Panel Structure Type

Satellite Structure Forms

Thrust Tube Structure Type

Korean STSat-2
Credit: earth.esa.int

Monocoque Structure Type

ESA Trace Gas Orbiter (TGO) SSTL Carbonite 1

Credit: spaceflight101.com Credit: directory.eoportal.org
Mass: 3.8 ton (Large-Satellite Class) Mass: 90 kg (Micro-Satellite Class)

KAIST STSat-3
Credit: kis.kaist.ac.kr 19
Project Lead Time
Longer project lead time
• Require less resource (design engineers)
• Lower risk of late design change
• Better structural performance (lower mass, easier to manufacture, easier to integrate)

Shorter project lead time

• Require more resource (design engineers)
• Higher risk of late design change
• May sacrifice structural performance
• Incur higher cost (fast track manufacturing cost, overtime)

Key to reduce project lead time

• Design for Manufacturing principle (more on this later)
• Clear and precise requirement
• Development and support tool and resources

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V-Diagram

Product Assurance &

Quality Assurance
In every process

Mechanical Sub-system

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Example: THEOS2-SmallSAT

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How to start the designing
⮚ The heart of satellite mission is “a payload”, but the payload can’t work alone without
support from “various avionic sub-systems”
⮚ We design “a spacecraft (S/C) structure” to accommodate both “payloads” and
“avionics” by assemble them together into one piece
⮚ We also design “the S/C structure” to make it’s compatible with “a selected
launcher”
⮚ Payload & launcher requirements mainly “drives” the S/C structural design
⮚ To verify a robustness & integrity of S/C structural design, structural analysis & test
shall be performed

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Exercise: THEOS2-SmallSAT
Which are mission requirements? Which are derived requirement?
• Lower Earth Orbit Earth Observation Satellite
• 3-years service lifetime
• 100-kg class SSTL’s carbonite platform
• Soyuz/ PSLV auxiliary bay
• Featuring AIS/ADS-B secondary payload
• Featuring Raspberry Pi based Third payload
• One deployable panel
• No-propulsion system
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Satellite Shape & Dimension
Things to be considered…

All avionic and payload shall be fit in this structure

- Size of main payload (i.e. imager)
- Amount of avionic system required
- Power requirement
High power consumption 🡪 need more solar cell area

It must be compatible with launcher

- Will it fit inside a launcher fairing?
- Will it fit inside a dynamic envelope?
- Will it fit with available separation system?

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Satellite Inside Rocket Fairing
Primary Passenger Auxiliary or Secondary Passenger

Launcher: Vega
Launcher: Falcon 9 Block 5
Credit: ARIANE Space
Credit: https://spaceflightnow.com/

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Structural Qualification Status List (QSL)
Equipment Qty.
Heritage Required modification from
Sub-system Unit Qualification (THEOS-2
Mission sub-system heritage baseline SmallSat)
Status
Structure General Structure Carbonite-2 C Change panel inserts technology from hot 1
bonded to cold bonded. (CAT C)
Small change in dimension (CAT B)
Structure Separation system Carbonite-1, A Same separation system 1
Carbonite-2
Payload Main imager payload Carbonite-2 C Change imager electronic from COTS to SSTL’s 1
Ceria camera
AOCS Torque rod Carbonite-2, A Change only position on S/C 3
many others
AOCS Sun sensor Carbonite-2, A Change only position on S/C 4
many others
Etc.

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Mechanical Engineer Roles

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Mechanical Design & Manufacturing Tools

CAD: Solidworks, CATIA, NX

CAD file control: Solidworks PDM, Enovia
CAM*: NC Solution, Cura

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Module Placement
Example of Pleiades-HR (High-Resolution Optical Imaging Constellation of CNES),
launched in 2009
https://directory.eoportal.org/web/eoportal/satellite-missions/p/pleiades

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 Structure Elements
Every S/C structures, whatever how much of complexity is, they usually comprise of a following
structure elements
Panels: thin walls designed to Monocoque structure: thin-
Trusses: a set of beams or struts
Beam, Bar, and Strut: enclose volumes or to provide a walled tubes (round or rectangular
connected together at angles
Long component that supported mounting surface for spacecraft cross-section) made of composite
which is stronger that a single
axial and lateral loadings equipment. Honeycomb sandwich skins with stiffener or sandwich
beam
panel is the most popular usage panels

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Material Selection
• Yield strength
• Stiffness
• Specific mass
• Thermal expansion coefficient
• Manufacturability
• Shelf life
• Outgassing
• Non-magnetic*
• Raw material cost
• Order lead time

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Manufacturing Technique
• CNC Machining
• CNC Turning
• Wire EDM (Wire cut)
• Laser cut
• 3D printing
• Honeycomb sandwich panel
• Injection molding
CNC – Computer Numerical Control
EDM - Electrical Discharge Machine

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Design for Manufacturing
✔ Reduce the total number of parts
✔ Develop a modular design
✔ Use of standard components
✔ Design parts to be multi-functional
✔ Design parts for multi-use
✔ Design for ease of fabrication
✔ Avoid separate fasteners
✔ Minimize assembly directions
https://www.innovationservices.philips.com/looking-

✔
expertise/manufacturing-systems-industry-40/design-for-
Maximize compliance manufacturing-assembly-and-testing/

✔ Minimize handling

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 THEOS-2 SmallSAT Example
Part/Component Manufacturing Technology Material
GNSS Antenna Riser CNC Turning Aluminium 7000 Series
S-Band Mounting Block CNC Turning / Machining Aluminium 7000 Series
X-Band Horn Antenna Wire Eroding EDM Aluminium 7000 Series
Module Box CNC Machining Aluminium 7000 series
Module Box Lid CNC Machining Aluminium 7000 Series
Connector Bracket CNC Machining Aluminium 7000 Series
Star Tracker Bracket Multiple Processes Titanium
Satellite Assembly Trolley Multiple Processes Multiple Materials
Deployable Panel Sandwich-structured composite CRFP skin, Perforated
Aluminium Honeycomb
Side Panel Sandwich-structured composite Aluminium skin, Perforated
Aluminium Honeycomb
Separation Plate Large CNC Machining Aluminium 7000 Series
Momentum Wheel CNC Turning Aluminium 7000 Series

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Procurement
⮚ In-house or external supplier
⮚ Procurement lead time
⮚ Compliance (export control)
⮚ Quality
⮚ Price
⮚ Minimum order quantity (MoQ)
⮚ Reliability, thrustworthy

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Inspection
⮚ From supplier
⮚ Inspection report
⮚ Product conformance report
⮚ Discrepancy report

⮚ Inspect to drawing
⮚ May require specific inspection tools
⮚ No need to inspect every dimension
⮚ Fit-check method applies

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THANK YOU!

Q&A
atipat@gistda.or.th

38
Spacecraft Mechanical Integration, Analysis,
Test, and Mechanical Related Roles
Introductory Course

Presented by
Panachai Santananukarn | panachai@gistda.or.th

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Contents
⮚ Integration ⮚ Mechanical Analysis
– Build Instruction – Launcher Environment
– Drawing – Failure Mode Evaluation
– Tackle Box – Analysis Tools
– Build Log, Mate/De-Mate Log – S/C Structural Analysis
– Discrepancy Report – Finite Element Model
– Mechanical Ground Support Equipment – Mechanical Loading
– Analysis Results

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Contents - Cont.
⮚ Mechanical Testing ⮚ Other Roles in Mechanical Team
– Vibration Tests – Mass Budget
– Mass Property Test – Working with AIT Team
– Pyro-Shock Test – Support Other Sub-Systems
– Micro-Vibration Test
– Material Testing ⮚ Other Potential Responsibilities
- Mechanism Engineer
- Propulsion Engineer

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Mechanical Engineer Roles

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Integration

Build Instruction Drawing Tackle Box

Build Log
Discrepancy Report
Mate/De-mate Log

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 Build Instruction
▪ As a step by step guideline
▪ To use in accordance to drawing
and tackle box
▪ No need to strictly follow the
instruction
▪ Assume fundamental mechanical
and integration knowledge
▪ When in doubt, ask module owner!

44
Drawing
▪ As a overall complete build perspective
▪ To use in accordance to build instruction and tackle box
▪ Give part number as well as quantity and location
▪ Assume fundamental drawing reading knowledge
▪ When in doubt, ask module owner!

Source:https://en.wikipedia.org/wiki/Engineering_drawing#/media/File:DIN_69893_hsk_63a_drawing.png

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Tackle Box
▪ As a handy fasteners, small bracket tray
▪ To use in accordance to drawing and
tackle box
▪ Each box represent sub-assembly (i.e.
Space Facing Facet, Earth Facing Facet)
▪ Give part number as well as quantity
▪ When in doubt, ask module owner!

Sorce: https://my-mould.en.made-in-china.com/productimage/wXeJdFmPrcrl-2f1j00kwTtopNJnszY/China-Multi-
Compartment-Customized-Plastic-Electronic-Parts-Partition-Box.html

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Build Log, Mate De-Mate Log
▪ To record every progress made during integration Build
Detail Date Signed
▪ To record mating, de-mating of each component sequence

▪ Prevent overuse fasteners 1 Fit Space Facing Facet xx/xx/xx AW

▪ Prevent loosen fasteners 2 Fit shear walls
▪ Allow better traceability 3 Fit X-band module
▪ If find any deviation, open the discrepancy report 4

Part Date Torque Date Date Torque Date

Description Signed Signed Signed Signed
number mate1 (N.m) De-mate1 mate2 (N.m) De-mate2
00123 X-Band module xx/xx/xx 10.7 AW
00884
00381

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Discrepancy Report (DR)
▪ Also known as Non-conformance report (NCR),
Corrective & Preventive Action Request (CPAR)
▪ To record every non-conformance, deviation, accident
occur
▪ Can be very negligible or major problem
▪ Assign to all relevant person
▪ Module review board meeting need for major DR
▪ Solution will be recorded for future build

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Mechanical Ground Support Equipment
▪ Lifting frame
▪ Integration trolley
▪ Transit case
▪ Spacecraft rotation frame
▪ Vibration test bed adaptor
▪ Thermal test bed adaptor
▪ Mass properties test bed adaptor
▪ Electromagnetic compatibility test table

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Structural Analysis
Structural analysis is an approach to predict a mechanical behavior of engineering product design
under its application loading.

With help of a computer aided engineer (CAE) alongside with computer aided design (CAD) widely
used in modern research & development (R&D) engineering, a complex product design problem can be
solved quickly without creating a lot of prototypes and doing a lot of tests as previously done in the past

The main goal of structural analysis in space industry is to evaluate the robustness, integrity of S/C
structural design and mechanical interaction between concerned equipment to increase a confident
before manufacturing.

It can be done iteratively alongside with S/C structural designing while it’s in a designing phase to help
revealing the problem and improving it earlier!

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Launcher Environment
Is the mechanical loads generated by launcher during assenting are
transmitted to the passenger (satellites) through its separation ring or
interface

Quasi-static acceleration (QS):

Caused by a steady-state acceleration of launcher (can be up to 9 g)
Dynamic loads Ares I-X Aerodynamic Transonic Soyuz Fairing Separation
⮚ Sine vibration: Credit: NASA Credit: ESA–P. Carril, 2014
Caused by a structural response of launcher body
⮚ Random vibration:
Caused by aerodynamic interaction between air & rocket, engine combustion, and
transmitted acoustic load through S/C mechanical interface (for <400 kg S/C class)
⮚ Vibro-acoustic:
Caused by high intensity acoustic noise generated by engine combustion & aerodynamic
effect that transmitted to S/C external surface by surrounding air (for ≥400 kg S/C class)
Transient Load
⮚ Pyro-shock:
Caused by pyro-technique device actuation (i.e. explosive boles) during a separation of
rocket stages, fairing, other S/C, and S/C itself
Rocket Engine Firing
Credit: NASA
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Failure Modes Evaluation on S/C Structure
Metallic Skin Insert - Core
Structure Bolt Slippage Bolt Gapping Bolt Yielding
Yielding Yielding Shear
Metallic Panel ✔
Sandwich Panel ✔ ✔
Fasteners ✔ ✔ ✔

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Failure Modes - Sandwich Panel
Core Shear & Face Yielding Insert - Core Shear Failure

Credit: Ralf S. and Dieter K.,

Numerical modelling of partially potted inserts in honeycomb sandwich
panels under pull-out loading, Composite Structures, Volume 203, 2018.

Credit: https://www.hexcel.com/

Credit: Steves and Fleck, 2004; Shivakumar and Chen, 2009

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 Fastener Yielding & Rupture

Failure Modes - Fastener Joints

Fastener Joints Slippage Fastener Joints Gapping

Credit: www.structuremag.org/?p=10652
Credit: www.eng-tips.com/viewthread.cfm?qid=455218 Credit: Nassar S.A., Yang X. (2013) Bolted Connections

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Mechanical Analysis Tools Finite Element Solver Software
🡪 Solve S/C mechanical analysis
problem
Finite Element Modelling Software
🡪 Create S/C mechanical analysis model
🡪 View the analysis result

Others
🡪 Calculate margin of safety of S/C mechanical parts
🡪 Calculate shock response spectrum to evaluate vibration
test profile

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S/C Structural Analysis
A Finite Element Analysis (FEA) is used to predict
⮚ Modal properties of S/C assembly and modules under launch configuration
- Natural frequencies
- Mode shapes
- Modal effective mass* Uses MSC NASTRAN software to solve and calculate this problem

⮚ Base forces of S/C separation system to evaluate vibration test profile

⮚ Stress analysis of S/C primary structure parts i.e. panels, thrust tube
- Under quasi-static acceleration, sine and random vibration loadings
- Then calculate a margin of safety to evaluate the strength against various failure modes

⮚ Vibration transmissivity between S/C separation interface and any modules or

equipment
- Under 1g-sine or random vibration
- Then, vibration response magnitude of each modules under any level of sine or random vibration
loading can be calculated by simply multiply the input profile with transmissivity curve
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 S/C Structural Analysis Model
This analysis model is known as “a finite element model (FEM)” which is needed to be
created to predict the structure behavior

1. Import the S/C CAD model design, and minimize detailed features

2. Define material & structure properties as per datasheet, supplier info, or material test
result

3. Simulate S/C configuration by applying an appropriate boundary condition to S/C

interface

4. Model validity checks shall be performed when FEM has been firstly created, and
every time that FEM has been updated to ensure a validity of FEM before uses

Credit: Jae Hyuk Lim,

A correlation study of satellite finite element model for coupled load analysis using
transmissibility with modified correlation measures, Aerospace Science and Technology,
2014.

57
Mechanical Loading

Credit : Adriano C., ESA Spacecraft Structural Dynamics & Loads An Overview. 2020

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 Analysis Results Vibration Response Analysis
(Predict vibration transmissivity, and vibration response of
Modal Analysis modules or equipment inside the S/C in each axis to support
module level development)
(Predict natural frequency, mode shapes, & modal
effective mass to evaluate S/C design)

Source: https://asrengineering.com/2018/12/18/how-spacecraft-survive-launch/

Credit: Israr, Asif. "Vibration and modal analysis of low earth orbit
satellite." Shock and Vibration, vol. 2014, 2014. Accessed 18 Mar. 2021.
59
Analysis Results – Cont.
Stress Analysis
(Predict MAXIMUM mechanical stress under quasi-static,
sine & random vibration to evaluate the robustness of
designed parts before manufacturing)

Credit: Kudzanai S. & Tawanda M. Finite Element Analysis of a Cubesat, Proceedings of the
2017 International Conference on Industrial Engineering and Operations Management (IEOM).
60
Mechanical Testing
Mechanical testing is another set of activities to be performed in order to verify the
mechanical sub-system requirement including

- Qualification test: to demonstrate a survivability of S/C or spaceflight hardware against

mechanical loadings during launch i.e. vibration test, shock test, acoustic test. This is a
mandatory test which needed to be complied as per structural verification plan and DDVP
approach.

- Material test: to determine material or structural properties which can be used to support
S/C structural and spaceflight hardware mechanical analysis (most reliable material
properties usually get from this test) and evaluate a workmanship build of mechanical part

- S/C mass property test: to determine mandatory mass properties of S/C and supply for
AOCS sub-system and launch agency needs

61
 Vibration Tests
As long as people still rely on rocket technology, S/C and flight
hardware vibration test is required to be done before launching the
S/C into space as per following reasons

- To de-risk a structure from failure & backfire during launch which

may leads the lost of mission, destroying other S/C or the whole
launcher!
- To increase a confident on a new S/C structure design by testing
them even stronger than launcher requirement to incorporate
additional margin for future development & usage

The S/C or flight hardware shall be tested on an electrodynamic

shaker or equivalent as shown in right picture. Several
accelerometers will be attached on test object interface to control
the vibration input and on critical location in S/C to capture the
vibration response Credit: Brüel & Kjær

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 Vibration Tests - Cont.
Vibration test is usually performed in three orthogonal axes (X, Y, and Z)
as mechanical loafing come from every direction
Three types of vibration tests are regularly performed
- Sine Dwell Vibration 🡪 demonstrate structure survivability against
quasi-static loading as this test profile is nearly equivalent to quasi-
static acceleration
- Sine Sweep Vibration
At low level (< 0.5 g) 🡪 to evaluate any structural changes or
damages on each stage of vibration tests by comparing current and
previous LLRS response
At high level (≥ 0.5 g) 🡪 to demonstrate structure survivability Spacecraft Vibration Testing in lateral direction
against sine vibration environment (10-100 Hz) Credit: NASA
- Random Vibration 🡪 demonstrate structure, modules, and
equipment survivability against random vibration environment (10-
2000 Hz)

63
Vibration Test Result Analysis
Once the tests are done, raw data capture from each tests still can’t be used instantly
and requires to do a proper post processing

For vibration test; Useful data is natural frequencies of primary structure, main
payload, and other vibration sensitive equipment i.e. battery

Vibration transmissivity is another important data needed to be extracted as it can be

used for predicting vibration response under higher level of vibration input

64
S/C Mass Property Test
The S/C (in flight configuration) shall receive a mass property test
using a mass properties measurement machine and S/C M.o.I rig
to extract mandatory information including
- S/C Mass
- S/C Center of Gravity (C.o.G)
- S/C Moment of Inertia (M.o.I)
- S/C Product of Inertia (P.o.I) - Optional

These information can be used as an input for a satellite altitude

controlling system and shall be submitted to AOCS engineer
straight forward.

Besides, launch agency also requires mass & C.o.G. information

as well!

65
Pyro-Shock Test
Some small electronic board components i.e. atomic clock,
piezoelectric crystal (and glass) are subjected to get damage
by shock loading causing by pyro-technique device actuation
during rocket stages, fairing separation, and S/C jettison.
If new or non-heritage shock sensitive component has been
introduced into an electronic board design or other instrument,
pyro-shock test shall be performed (usually at module or
equipment level) in a shock rig to evaluate a survivability of
these component against shock loading.
Credit: ESA

If it pass the test, the component will get shock If the component is found broken after test,
qualification and can be used in other unit or in new part shall be replaced, or design change
future mission without any further test may be introduced, then repeat the test again.

66
 Pyro-Shock Test - Cont.
Pyro-shock test can be performed at S/C
level as well by using an engineering
model (EM) separation system which
contains a set of explosive bolts.

BepiColombo Mercury Spacecraft Structural Model – Shock Test

Credit: https://sci.esa.int/web/bepicolombo/-/50681-
bepicolombo-composite-spacecraft-separation-shock-testing

67
Micro-Vibration Test
In some S/C that equipped with a pointing sensitive instrument
i.e. imager, a vibration at very low magnitude generated by on-
board mechanism can cause an instability (a small vibration) to
the imager. If this happens during capturing the image, it may
cause the photograph to be distorted or blurred.
This phenomenon is called “a jitter effect”.
With a combination of decent S/C structure, mechanism, and
imager design, the micro-vibration response at the imager can
be controlled in a satisfied limit.
There’re only two ways to evaluate the imager micro-vibration
performance, by analysis, and test. However, if the imager
pointing requirement is really needed to be complied, the micro-
vibration test may be performed at S/C level to predict
Jitter Effect on Satellite Imagery
a maximum pixel shift that could happens in orbit.
Credit: Cornelius J. Dennehy,
SURVEY OF REACTION WHEEL DISTURBANCE MODELING APPROACHES
FOR SPACECRAFT LINE-OF-SIGHT JITTER PERFORMANCE ANALYSIS, NASA

68
Micro-Vibration Test – Cont.
To simulate in orbit configuration of the S/C
as close as possible, the S/C will be slightly
lifted from the ground and hanged by a
springy bungee cord. Then, reaction wheels
will be commanded to run in a proper
approach and several accelerometers
attached to the imager will capture the
micro-vibration response, then the pixel
shift can be predicted.

Credit: Shan-Bo C. et al., Simulating and Testing Microvibrations on an Optical Satellite Using
Acceleration Sensor-Based Jitter Measurements, 2019.

69
Material TestingIn some occasions, mechanical team may request some additional
material testing in order to get some useful information to support their
job. For example.

- Stiffness testing
To extract a stiffness property of S/C component (i.e. isolation rubber mount) and
update into the S/C structural analysis model (FEM) to correlate the mechanical
behavior against vibration test result

- Strength testing
To evaluate the workmanship build quality and performance of S/C part (i.e.
sandwich panel) against potential mechanical loadings.
This test requires sets of test coupons (a small piece of material which represent
that S/C part, made in various forms to suit individual material test). It
usually built from the same production lot of that part.
The test may includes (depends on function of a parent part)
Universal testing machine - a flexural strength test
Credit: Wikipedia
- an adhesive peel off strength
- an insert pull out/shear strength
70
Other Roles in Mechanical Sub-System

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Mass Budget
• Owns by Mechanical team
• Use for Structural Analysis, AOCS performance, Launch
• Consistent with system level and other sub-system
• Breakdown to sub assembly level
• Can trace down to each module, bracket and fasteners
• Contains mass, center of gravity (CoG), inertia respect to the spacecraft origin
• Preliminary CAD margin 10-20%
• Critical Design Review CAD margin 5-10%
• Actual weighted margin 0-2%

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 Mass Budget Sub-system Unit Total mass CoG (X) CoG (Y) CoG (Z)
w/t out unit Wrt. Wrt. Wrt.
Total mass without unit level margin S/C origin S/C origin S/C origin
Sub-system
level margin [kg] [kg] (mm.) (mm.) (mm.)

AOCS 7.5 AOCS Sun-sensor-0 0.12 271.0 250.4 -15.0

Power 15.0 AOCS Sun-sensor-1 0.12 271.0 -249.4 -15.0

Communication 0.9 AOCS Gyro-0 0.15 140.6 10.2 240.5

Central processing 3.1 AOCS Wheels-0 3.1 175.1 164.3 445.2

Environment control 1.0 AOCS Wheels-1 3.1 -173.4 164.3 445.2

Structure 43.5 Structure Space Facing Facet 15

Harness 5.6 Structure Shear panel +X 5.6

Payload 23.4 Structure Shear panel -X 5.8

TOTAL MASS 100.0 Structure Shear panel -Y 6.0

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Working with AIT Team
• Mechanic team lead the initial spacecraft integration with support from AIT team
• AIT team then later prepare the spacecraft for series of test
• AIT might ask for support from mechanical team i.e. to rotate the spacecraft, to
integrate/ remove main payload
• Every discrepancy with the spacecraft structure during AIT phase will be reported to
mechanic team

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Support Other Sub-System
• Mechanic team owns spacecraft configuration and mass budget
• Mechanic team will design the spacecraft to be easy to assembly, integration and test
• The component placement could change by request from sub-systems
• AOCS might ask to provide images of the location of the ACOS equipment
• Sub-systems might ask mechanical team to produce module box, radiation shield, extra
adaptor plate, etc.

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Other Potential Responsibility

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Mechanism Engineer
• Hinges
• Focus Mechanism
• Antenna Pointing Mechanism
• Reaction wheels
• Hold down and release mechanism

Credit:
https://directory.eoportal.org/web/eoportal/satellite-
missions/content/-/article/nigeriasat-2

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Credit: https://ntrs.nasa.gov/api/citations/20150004077/downloads/20150004077.pdf
Propulsion Engineer
• Propulsion budget estimation
• Propulsion system selection
• Propulsion system design, manufacturing,
integration and test
• Small thruster design
• Propulsion Ground Support Equipment

Credit: https://directory.eoportal.org/web/eoportal/satellite-missions/d/dmc

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THANK YOU!

Q&A

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