Design of a CubeSat Separation

Mechanism
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Project 04-17-06

Team Members: Gregory Bosma

Andrew Drummond
Ross Hiller
Faculty Mentor: Dr. Koorosh Naghshineh
Industry Mentors: Dr. Kristina Lemmer
Nagual Simmons
Sponsor: Western Aerospace Launch Initiative (WALI)
Additional thanks to: Mike Konkel

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Outline

• Background
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• Design Requirements
• Design Options
• Option 1: Linear Actuator Pin-puller
• Option 2: Ejector Release Mechanism
• Simulations
• Fabrication & Assembly
• Testing
• Conclusion
• Recommendations

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Background on CubeSats

• CubeSats are small spacecraft

usedClick
for:to edit Master title style
• Research
• Broadcasting
• Space exploration:
• Missions around the moon
• Missions to Mars
• Their standardized geometry
allows for production of off-the
shelf components
• This significantly reduces cost
of the spacecraft

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Project Scope
• An upcoming experiment requires a CubeSat capable of splitting into two
bodies.
• For Click
this project: design,
to edit Master title simulate,
style prototype, and test a mechanism
capable of separating a CubeSat while in orbit
• NOTE: The satellite is in a very early design phase

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Design Requirements

• Design volume of 211.8 x 100 x 60mm

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(8.339 intox edit
3.937Master title style
x 2.362 in) maximum
• Acts as one face of each CubeSat
• No debris created by separation
• Maximum mass of 0.7 kg (about the
weight of a basketball)
• Maximum separation velocity of 8
cm/s
• Minimize rotation caused by
separation
• Utilize redundant systems
• Comply with CubeSat structural
requirements

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Design Options:

• Developed two designs utilizing different release devices

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• Option 1: separated by a linear actuator releasing a pin
connection between the plates
• Option 2: incorporates an off-the-shelf aerospace release
mechanism between the structural baseplates

Option 1 Option 2

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Features in both options:
Baseplates
• Act as main structure for
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the mechanism Option 1 Option 2
• Mounts to rest of satellite
structure
• Act as one face of each
satellite

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Features in both options:
Alignment Legs
• Designed in a cup-and-cone
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configuration
• Minimizes risk of binding
• Allows two satellites to stay
aligned before separation

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Option 1: Pin-Puller Design

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Features of Option 1:
Pin Connections
• One of the simplest methods of
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connecting andMaster title style two
disconnecting
bodies
• Easily resettable

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Features of Option 1:
Linear Actuators
• Intended to pull pin and allow
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separation
• To actuate, a stepper motor
rotates to drive a leadscrew.
• Selected Haydon Kerk Part #
19343-05-A16
• Minimizes cost
• Vacuum-rated
• Wide operating temperature range
• Minimizes electrical energy
consumption

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Features of Option 1:
Chain Link
• Allows two different pin
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connections toMaster title style
be used
• Only one pin must be
pulled to separate
• If one pin cannot pull, the
other pin may be used

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Features of Option 1:
Springs
• Springs push satellites
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apart onceto edit Master title style
disconnected
• Selected custom spring
plungers from cubesat.org
• Will not create debris
• Used in many previous
CubeSat missions
• Tested springs for force
vs. travel to find closest
matching pair
• Test data also used to
adjust separation velocity

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Option 2: Design using off-the-shelf
Ejector Release Mechanism (ERM)

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Features of Option 2:
Ejector Release Mechanism (ERM)
• Built-in latching system
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• Built-in spring
• Has been used in many
similar applications
• Extensive testing done by
supplier
• Much higher cost than
linear actuators

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Comparing Options:
Option 1 (with pin connections)
• Much lower cost than option 2
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• Meets all mission requirements
• Requires extensive testing to
become qualified
Option 2 (with ERM)
• Has been used in many similar
applications
• Fewer components than option 1
• Benefits manufacturability
• Reduces amount of failure points
• Extensive testing done by
supplier
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Fabrication and Assembly:

• Fabricated both designs on

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campus
• Baseplates are CNC
machined
• All other components are
machined with manual
lathe and mill

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Simulation and Testing Methods

• Finite Element
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Analyses:
• 35G static loads
• Frequency analysis
• Random vibration
loads
• Pendulum testing:
• Intended to test
mechanism as if it
were in orbit
• Used to validate
calculations

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Static Simulations

• Simulating loads
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expected edit Master
launchtitle style

• Run using finite element

analysis software.
• Simulated 35G
acceleration in X, Y, and
Z directions
• Pin constraints at all
points mounted to
structure (shown in
green in above picture)
• Bolt preloads added to
simulation.

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Frequency Simulations

• Found natural frequency &

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shapes
• Constrained mechanism at
bottom
• Lowest natural frequency
found is 502Hz
• Well above minimum
frequency of 100Hz

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Random Vibration Simulations

• Constrained at bottom of
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mechanism
• Added vibrational loads to
bottom of mechanism
• Found RMS stresses:
• 21.65 MPa maximum in all cases
• Well below failure limit of
73.33MPa

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Pendulum Test: Setup

• Each satellite is suspended

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independently
• Actuation is triggered remotely
• This allows us to see the mechanism in
action
• Each test is recorded on video
• Separation velocity is measured through
frame-by-frame analysis

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Pendulum Test Video

• Pendulum length is
5.13Click to edit Master
m (16.83 ft) title style

• Alternate masses
are used to validate
the test setup:
• E-Sat mass of 2098
grams
• D-Sat mass of 524
grams
• Since satellites are
lighter than
expected, they will
go faster than 8cm/s
• Expected velocity:
30.09cm/s
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Pendulum Test: Results

Relative Distance vs. Time

• Distances were 8
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measured in first 7 title style
frames (0.2 seconds) 7
y = 29.251x - 38.496
R² = 0.9906
after separation
Relative Distance (cm)
6

• Expected separation 5
velocity from
calculations: 30.09 4

cm/s 3

• Experimental 2
separation velocity:
29.25 cm/s 1

• Percent error: 2.79% 0

1.3 1.35 1.4 1.45 1.5 1.55 1.6
Elapsed Time (seconds)

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Conclusion

• Two separation mechanism designs were created

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• Option 1 (using pin connections)
• Option 2 (using off-the-shelf mechanism)
• Simulations of both designs show they can both withstand expected loads
• Option 2 is highly recommended
• Option 1 requires much more testing to be qualified for space
• Both designs were fabricated.
• Option 1 functions as working prototype
• Option 2 is incomplete; need to order ERM

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Recommendations

• Re-run pendulum tests:

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• Set springs for a predicted velocity of 8cm/s
• Use camera with higher resolution and frame rate for higher accuracy
• If pendulum test cannot provide accurate measurements, switch to air
table testing.
• If WALI decides to use Option 1:
• Optimize the design for weight reduction.
• Run random vibration, shock, vibration, thermal, and vacuum chamber tests

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Questions?

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