Proceeding of the 2015 International Conference on Space Science and Communication (IconSpace), 10-12 August 2015, Langkawi, Malaysia

Development and Design Challenges in VELOX-I

Nanosatellite
L.S. Lim, T.D.V. Bui, Z. Lau, M.S.C. Tissera, J.J. Soon, J.M. Lew, H. Aung, C. Ye, K.S. Low,
S.T. Goh and S.S. Chen
Satellite Research Centre, School of Electrical and Electronic Engineering
Nanyang Technological University, Singapore

Abstract— VELOX-I is a student built 3U Cubesat in Nanyang The VELOX-I communication is conducted at the
Technological University, Singapore. It has been successfully downlink frequency of 145.979 MHz and uplink frequency of
launched in 30 June 2014. The VELOX-I development 437.312 MHz. The ground station is located at the rooftop of
process has been improved through the past picosatellite South Spine building, NTU (Grid location: OJ11ui), which has
development and operation experience. However, the design been extensively used for ground communication with
of several key components has to be carefully considered as VELOX-PII (NTU first student built picosatellite) since it has
the VELOX-I have more complex missions and payloads. been launched.
This paper discusses the challenges of VELOX-I design, and
Up to current date, both the remote sensing and GPS
the alternative solution proposed by the team. These
missions have been successfully conducted. The VELOX-PIII
challenges include the in-house design deployment
will be only conducted as the very last VELOX-I mission
mechanism, optical extension tube, multi-layer insulator and
because releasing the VELOX-PIII requires an extensive
impact of 3U Cubesat structure on the communication
conjunction analysis to avoid any potential clash with other
system. Each design is required to meet several requirements
satellite.
such as operating temperature, overall thickness and satellite
mass. In summary, the success of VELOX-I ground contact This paper presents several design challenges and
and primary payload mission have proven the flight heritage constraints encountered by VELOX team during the
of the presented design solutions. development and test processes. Similar to the other standard
3U Cubesat, the VELOX-I is required to have a dimension of
Keywords- VELOX-I; Cubesat; Optical Extension Tube; 10cm x 10cm x 34cm with the maximum mass of 4.3kg. This
Thermal Knife; Heat insulation is to ensure the VELOX-I can be inserted into the Cubesat
launch pod, and it could be deployed at desired velocity.
I. INTRODUCTION Based on the physical constraint, the VELOX team has to
ensure the harvested solar energy is sufficient to support the
Small scale satellite has been received much attention from
VELOX-I mission operation. In addition, the mechanical
both industrial and academia, especially during the past
design of VELOX-I, such as deployment mechanism for both
decade due to the shorter development time and lower costs
optical extension tube and solar panels are required to be high
[1]. For example, the Planet Labs has launched more than 93
durability and repeatability. The design consideration of these
Doves series nanosatellites in 2014. In addition, the team only
components using a non-conventional method is discussed in
requires as short as two weeks to assembly two nanosatellites
this paper. Also, lack of communication expertise in VELOX
for launch [2]. It is predicted that more than 500 small scale
team exposes the VELOX-I development to a threat which the
satellites will be either under development or launched within
impact of VELOX-I structure on communication performance
next five years [3].
is overlooked.
VELOX-I, as shown in Fig. 1 (details in TABLE 1) is a 3U
(10cm x 10cm x 30cm) Cubesat built by students in Nanyang
Technological University (NTU) [4, 5]. It has been
successfully launched in 30th June 2014 by India Space
Research Organization (ISRO). VELOX-I carries an in-house
developed gray-scale Complementary metal-oxide-
semiconductor (CMOS) image sensor [6] with an extendable
optic, a GPS receiver and a deployable smartphone size
picosatellite, VELOX-PIII. In addition, the subsystem
components, such as the power subsystem, attitude
determination and control subsystem (ADCS), fine sun
sensors and three-axis reaction wheel are developed by
students.

Figure 1. VELOX-I flight model.

978-1-4799-1940-6/15/$31.00 ©2015 IEEE 158

Authorized licensed use limited to: University of Adelaide. Downloaded on August 29,2023 at 14:44:17 UTC from IEEE Xplore. Restrictions apply.
 TABLE 1. VELOX-I TECHNICAL SPECIFICATION.
Dimension 100mm x 100mm x 340mm (VELOX-I)
60mm x 70mm x 30mm (VELOX-PIII)
Total Mass 4281 grams
Orbit Sun-synchronous LEO
650 km altitude
Power 4 deployable GaAs panels for 28.8W peak
subsystem 5200mAh Li-ion battery
Thermal Multi-Layer Insulation (MLI), battery heaters
control
Payloads CMOS image sensor with extended optics for
21m ground resolution, GPS receiver, VELOX-
PIII
Ground 1200bps BPSK downlink at 145.979 MHz and
segment 1200bps AFSK uplink at 437.312MHz
This result the communication interference has been
observed during the qualification and flight models (QM and
FM) integration, and a counter measure is needed to be taken.
This paper is organized as follow. First, the VELOX-I
mission objective is presented. Then, section III presents the
mission operation power requirement of VELOX-I. Section IV
to VI presents the in-house designed deployment mechanism,
optical extension tube cover and heat insulation layer
respectively. Section VII presents the impact of VELOX-I
structure on communication performance, and followed by a
summary.
II. MISSION
VELOX-I’s primary objective is to provide an opportunity
for students in NTU to experience the nanosatellite
development and operation. More than 100 undergraduate
students have been involved in the VELOX-I development or
related programme. The subsystems, ADCS, power subsystem
and inter-connect subsystems developed by both
undergraduate and graduate students, have been successfully
proven for flight heritage in VELOX-PII.
The primary payload, CMOS sensor camera is an in-house
built sensor with radiation–hardened design to reduce the
leakage current and voltage shift. It captures a greyscale earth
image with the resolution of 768x512 with expected 20 to 30
meter ground sampling distance. In addition, VELOX-I will
demonstrate a fast GPS time to first fix (TTFF) algorithm. The
GPS receiver requires more than 20 minutes to track GPS
satellite and determines its own position without the fast TTFF
algorithm due to high relative velocity environment in LEO.
Figure 3. In-house deployment mechanism. Left to Right: CAD drawing design, second design (full MACOR), and final design.
159
Authorized licensed use limited to: University of Adelaide. Downloaded on August 29,2023 at 14:44:17 UTC from IEEE Xplore. Restrictions apply.
Figure 2. VELOX-I whole orbit power budget analysis.
The algorithm allows the GPS receiver to be able to track
GPS satellite and resolves its location in a shorter TTFF. The
demonstration is important because the subsequent satellite
program, VELOX-CI and VELOX-II requires a fast TTFF to
allow longer mission time to conduct radio occultation
experiment. Furthermore, VELOX-I will demonstrate an
experimental inter-satellite communication experiment through
XBee module. The VELOX-PIII will be deployed using a
compression spring mechanism [4].
III. POWER BUDGET ANALYSIS FOR BATTERY SIZING
Both battery and solar panel configurations play an
important role in the satellite design. Based on VELOX-PII
experience, the battery depth of discharge is required to be no
more than 25% in order to maximize the battery life [7]. Fig. 2
presents the worst case scenario power budget analysis of each
VELOX-I subsystem. It shows that the highest power
consumption occurs during the camera payload mission,
which is expected.
By considering that the time duration of the camera
payload mission is 15 minutes, and the total energy used
during eclipse period of 4.46 Wh, the minimum capacity
required for battery configuration, to meet both 25% depth of
discharge and 30% capacity fading requirements is 5.2Ah.
The estimated total energy used during sunlight period is
8.36Wh. To ensure the solar panel is capable of recharging the
battery (begins at 25% depth of discharge) while supplying
sufficient power to VELOX-I subsystem during sunlight period
for mission operation purpose, at least 12.8Wh input from solar
panel is required. By taking both power converters and
maximum power point tracking algorithm losses into
consideration [7], the VELOX-I requires all four 3U solar
panels to be simultaneously pointing to sun for energy
harvesting
purpose.
 TABLE 2. DUTY CYCLE VS TEMPERATURE.
Duty Cycle TK Temperature
40% +175 degC
60% +243 degC
70% +269 degC
80% +335 degC

This allows an average of 14Wh of power (or maximum of

28.8W) could be collected during the sunlight period. In other
words, the power analysis requirement indicates that a
deployable solar panel mechanism is required.

IV. IN-HOUSE DEPLOYMENT MECHANISM

The deployable solar panel requirement by power budget
in section III and the VELOX-PII operation experience has
motivated the VELOX team to design a high reliable,
durability and robust deployment mechanism. Although
VELOX-PII antenna deployment mechanism is commercial-
off-the-shelf (COTS) component, but it has a limited
durability as stated in the technical specification. Therefore, it
is not advisable to conduct the antenna deployment test after
full satellite stack up assembly to maintain full durability of
deployment mechanism upon launch. This results the antenna
deployment clearance and functionality are not fully
confirmed prior to launch.
The in-house designed thermal knife (in Fig. 3) is based on
majority Cubesat deployment mechanism [8-10]. The
deployable structures, such as solar panels, camera lens
extension tube and antenna are connected and holded by a
nylon wire. The nylon wire are then cut (or technically,
melted) by a thermal cutter through heating process to release
all the deployable structures. While some COTS component
uses resistor as thermal cutter, we consider the nichrome wire
(housed in a casing) because it has a higher durability.
The polyether-ether-ketone (PEEK) was initially selected
as the thermal knife casing because it has lower fragility,
weight and cost. However, its lower melting point at 340
degree Celsius [11] results a shape deformation (or melting)
has been observed during high duty cycle of current input (at
80%). The PEEK experiences at least 335 degree Celsius (see
TABLE 2) which is close to PEEK’s melting point. Therefore,
an alternative material for the casing is needed.
The final in-house design thermal knife consists of a cap
(aluminum), a casing (ceramic) and a thermal cutter (nichrome
wire) as shown in Fig. 3. The nichrome wire is coiled inside
the casing with the nylon wire passes through the two holes.
The machinable glass ceramic (MACOR) is selected as the
casing because it has an extreme high operating temperature,
approximately 800 degree Celsius [12].
Figure 4. VELOX-I FM in stowed condition.
Furthermore, MACOR has lower thermal expansion and
thermal conductivity than aluminum, which provides a better
efficiency on deployment process (lower heat loss from
nichrome wire).
An aluminum cap is introduced as strength reinforcement
for the designed thermal knife because MACOR is more fragile
than PEEK. The aluminum reinforcement would minimize the
probability of damaging the MACOR casing during satellite
stack up, transportation, launch and ejection process.
To qualify the thermal knife design, both low and high
temperature environment experiments have been conducted, at
-20 degC and 60 degC. The high duty cycle current is supplied
into the thermal knife for 10 times at 1 minute interval. The
first current supply is to ensure the nylon wire can be melted by
nichrome wire at both low and high temperature environments,
while the next 9 current supplies is to ensure the durability of
the designed thermal knife. Visual check has been performed
after the experiment, and the nylon wire cutting process is
repeated in room temperature to confirm the functionality of
the thermal knife after the experiment.
V. OPTICAL EXTENSION TUBE
The focal length of the optical payload is approximately
17cm. However, the size constraint of VELOX-I requires an
extendable optical tube design instead of a fixed length design.
There are several constraints in the optical extension tube
design: The maximum thickness of extension tube under stow
condition (shown in Fig. 4) is 2mm, and it is required to have
low out-gassing characteristic.
The bellow lens design using Aluminized Kapton was
considered during initial design phase.

Figure 5. Camera lens with ESD material optical extension tube deployment test.

160
Authorized licensed use limited to: University of Adelaide. Downloaded on August 29,2023 at 14:44:17 UTC from IEEE Xplore. Restrictions apply.
 However, it exceeds the maximum thickness requirement.
As a result, the electrostatic discharge (ESD) cloth has been
chosen as the optical extension tube material. The ESD cloth
is a highly flexible material, it does not require to be folded
into a specific shape under stow condition, which ease the
repetitive deployment test process during qualification phase.
Fig. 5 presents flexibility of ESD cloth when it is used as the
optical extension tube through a simple deployment test.
Because the outgassing particle in space could results in
image quality degradation by contaminating the optical
payload, a 24hr thermal baking process has been conducted on
the ESD cloth to ensure there is not outgassing occurs.
Furthermore, the designed optical extension tube was first
verified on the ground by taking the image of a moon (see Fig.
6) during focal length confirmation process. In addition, the in-
orbit remote sensing experiment has been confirmed that the
ESD cloth could be a suitable candidate for low cost space
camera optical extension cube. Figure 7. Flight model stack up without MLI installed and
solar panels are fully deployed.

While high reflectivity could reflect more sun light

radiation heat, but it will contains more heat generated by each
subsystem, which mean less heat generated could be
dissipated. On the other hand, high emissivity could dissipate
more heat generated by each subsystem into space, but it also
allows more radiation heat from sun light to be absorbed into
satellite bus system.
Fig. 9 shows that 4 MLI layers could prevent
approximately 60% thermal radiation absorption of direct
sunlight by satellite system. However, the overall thickness
using 4 MLI layer is approximately 1.5mm, which exceeds the
thickness constraint. Therefore, only 2 MLI layers design is
considered.
Figure 6. Moon image taken by VELOX-I camera To qualify the designed 2-layer MLI, an experiment has
been conducted to simulate the temperature difference of MLI
surface between direct sun light exposure and non-direct sun
VI. HEAT ISOLATION
light exposure through the sun simulator. Fig. 10 shows that at
The deployment of VELOX-I solar panels for sun tracking least 40 degree Celsius temperature difference between the
purpose imposes the threat of all subsystems are being directly surface with direct sun light exposure and the surface under
exposed to sunlight in space environment (see Fig. 7). Thus, a MLI protection.
passive heat insulation method is required.
The heat insulation method is required to has a thickness
less than 1mm, and fulfill the total satellite mass constraint of
4.3kg. Although 1mm aluminum sheet could be used for
passive heat insulation purpose, but using 4 sheets 10cm x
3cmm x 1mm aluminum sheet exceeds the satellite total mass
constraint. In addition, the satellite harnessing also prevents
the direct installation of aluminum sheet on the structure.
Therefore, the multi-layer-insulation (MLI) is considered as
the alternative heat insulation method.
The designed MLI consists of fiber glass mesh, metalized
Mylar and Kapton sheet (see Fig. 8). An analysis has been
conducted to study the efficiency of proposed MLI with
respect to different MLI layer, where one MLI layer is defined
as one pair of metalized Mylar and Kapton sheet. It is noted
that the performance of MLI is evaluated with respect to the
emissivity and reflectivity of material in each layer. Figure 8. The MLI materials: #1 and #7 are kapton sheet, #2 and
#6 are fiber glass mesh, #3 and #5 are metalized mylar, #4 is for
cutting reference, and #8 is the finished MLI.

161
Authorized licensed use limited to: University of Adelaide. Downloaded on August 29,2023 at 14:44:17 UTC from IEEE Xplore. Restrictions apply.
 Figure 10. Thermal emissivity w.r.t. number of MLI layers.
In addition, Fig. 11 presents the real time in-orbit
temperature data for ADCS, on-board data handling (OBDH)
and power subsystems. The results confirm that the designed
MLI is capable of maintaining the subsystem temperature
within expected operating temperature, which is less than 55
degree Celsius. Both ADCS and inertial measurement unit
(IMU) temperature data are only available after 11 minutes
because the ADCS is powered on 10 minutes after orbit
insertion by launch vehicle. In addition, the ADCS has a
higher operating temperature due to the reason that both
ADCS and communication subsystems consume the highest
power usage among all satellite subsystem. In addition, the
IMU is installed on the ADCS board. Furthermore, both
ADCS and communication subsystems are located next to
each other. The radiation heat exchange between two
subsystem results ADCS has a higher operating temperature
than other subsystems.
Similar phenomena can be explained for the OBDH
operating temperature. The OBDH was installed right beneath
the communication subsystem and the communication
subsystem is only powered on approximately 50 to 60 minutes
after orbit insertion. Fig. 11 shows that the OBDH temperature
significantly increases for 10 degree at 50 to 60 minutes mark,
which is the time period when the communication subsystem is
powered on.
VII. COMMUNICATION INTERFERENCE
The VELOX-I uses similar COTS communication system
as in VELOX-PII, which has proven its flight heritage in
several Cubesat programs. However, a consistence downlink
noise has been observed during QM/FM the communication
test (see Fig. 12). The downlink noise results all received
signals are unable to be successfully decoded.
A series of experiments have been conducted to study the
source of downlink noise. The results indicate the particular
issue only exists in QM/FM models. Although we initially
suspect that the communication subsystems in both QM and
FM have been damaged; however, the downlink noise persists
after the replacement of new communication subsystem.
In addition, a high return power, approximately 50mW has
been observed during signal transmission, which was
identified as the possible cause that damages the
communication subsystem.
162
Authorized licensed use limited to: University of Adelaide. Downloaded on August 29,2023 at 14:44:17 UTC from IEEE Xplore. Restrictions apply.
Figure 11. Two layers MLI heat insulation experiment.
A detail investigation has been carried out on the FM.
Based on the observation that the downlink noise only persists
on the QM/FM structures; the antenna mismatching issue
could be the possible root of cause that results a high return
power. The mismatching problem is suspect to be occurred at
the output port of transmission’s high power amplifier in the
communication subsystem. Although perfect matching is not
possible, however, a low reflection coefficient by the amplifier
is expected at designed working frequency band. If the high
power amplifier is sensitive to the change of either load
impedance or frequency, it may results a high reflective power
coefficient. This would results the signal reflected by either
3U structure or solar panel is being amplified at a power
higher than expected, thus results damage in communication
subsystem.
There are two solutions to solve antenna mismatching
issue: (1) trim the antenna length, or (2) install an attenuator.
Trimming the antenna length has the advantage of the link
budget remains unchanged. However, antenna trimming is an
irreversible process and requires a specialist. On the other
hand, attenuator installation is a reversible process, but an
updated link budget due to lower transmission power is
required to be reconsidered.
Due to the fact that performs an antenna trimming in a short
time frame is not feasible, the attenuation installation has been
considered as the solution. A further communication test with 2
dB attenuator shows that a clear signal can be obtained and
decoded (see Fig. 13).
Figure 9. VELOX-I first orbit subsystems temperature data.
 Figure 13. Consistent downlink noise observed. Figure 12. Downlink noise removed with attenuator installed.

[6] X. Qian, H. Yu, S. Chen, and K. S. Low, "An Adaptive Integration

This proposed solution has been further confirmed through
the successful ground communication establishment after the
launch. The VELOX-I communication issue experience allows
us to learn the impact of satellite structure on communication
subsystem durability. It is suggested that the simulation
analysis on impact of satellite structure on antenna
transmission’s reflective power should be conducted during the
early stage of satellite design.
VIII. DISCUSSION SUMMARY
The in-orbit satellite data of the VELOX-I indicates a
simple and low cost design is suitable for Cubesat application,
such as the deployment mechanism using MACRO and the
optical extension tube using ESD cloth. In addition, the in-
orbit data shows the heat insulation still remain as the major
concern in Cubesat development, such that the heat insulation
design is limited by Cubesat overall thickness and harnessing
constraints. On the other hand, the lesson learned from
communication issue allows us to realize that it is required to
conduct antenna configuration and satellite structure analysis
during the early stage of satellite design.
Time CMOS Image Sensor with Multiple Readout Channel," IEEE
Sensors Journal, vol. 13, pp. 4931-4939, 2013.
[7] L. J. Min, H. Aung, J. J. Soon, and K.-S. Low, "In-Orbit Performance
of VELOX-PII Power Management System," in 30th International
Symposium on Space Technology and Science, 34th International
Electrical Propulsion Conference & 6th Nano-Satellite Symposium,
Kobe, Japan, 2015, pp. 1-6.
[8] S. Jeon and T. W. Murphey, "Design and Analysis of a Meter-Class
CubeSat Boom with a Motor-Less Deployment by Bi-Stable Tape
Springs," in 52nd AIAA/ASME/ASCE/AHS/ASC Structures,
Structural Dynamics and Materials Conference, Denver, CO, 2011, pp.
1-11.
[9] K. Nakaya, K. Konoue, H. Sawada, K. Ui, H. Okada, N. Miyashita, et
al., "Tokyo Tech CubeSat: CUTE-I - Design & Development of Flight
Model and Future Plan," in 21st International Communication Satellite
Systems Conference and Exhibit, Yokohama, Japan, 2003, pp. 1-10.
[10] J. M. E. Plaza, J. A. V. Vilán, F. A. Agelet, J. B. Mancheño, M. L.
Estévez, C. M. Fernández, et al., "Xatcobeo: small mechanisms for
cubesat satellites antenna and solar array deployment," in 40th
Aerospace Mechanisms Symposium, NASA Kennedy Space Center,
2010, pp. 415-429.
[11] Victrex, "PEEK Material Properties Data Sheet," AFTON
Plastics2014.
[12] "MACOR: Machinable Glass Ceramic For Industrial Applications,"
Corning SAS2012.

In overall, the success of ground contact of VELOX-I and

primary payload mission has verified the VELOX-I
development. The result justifies that a non-conventional
innovative solution could be implemented for Cubesat
application as the Cubesat mission life time is often shorter
than commercial satellite product.

REFERENCES
[1] S. L. Xie, G. X. Lee, K. S. Low, and E. Gunawan, "Wireless Sensor
Network for Satellite Applications: A Survey and Case Study,"
Unmanned Systems, vol. 2, pp. 261-277, 2014.
[2] R. Holm and S. Spanhake. (2015, March 3 2015). Planet Pulse.
[3] E. Buchen, "SpaceWorks' 2014 Nano/Microsatellite Market
Assessment," presented at the 28th Annual AIAA/USU Conference on
Small Satellites, Logan, UT, 2014.
[4] S. T. Goh, Z. Lau, and K. S. Low, "An Optimization Method for Nano-
satellite and Pico-satellite Separation through a Two Mass-One Spring
System," in AAS/AIAA Astrodynamics Specialist Conference, Hilton
Head, SC, 2013, pp. 723-743.
[5] T. D. V. Bui, K. S. Low, Z. Lau, V. H. P. Pham, and M. S. C. Tissera,
"System Design and Development of VELOX-I Nanosatellite," in
IEEE Aerospace Conference, Big Sky, MT, 2015, pp. 1-7.

163
Authorized licensed use limited to: University of Adelaide. Downloaded on August 29,2023 at 14:44:17 UTC from IEEE Xplore. Restrictions apply.