MIDSTAR

1
MIDSTAR
2
MIDSTAR TEAM

• Caleb Bauer
• Rebecca Baumez
• Ethan Biter
• Paul Camp
• Katherine Groenenboom
• Cale Johnson
• Sean Jones
• Kevin Yost

3
AGENDA

• IntroductionCol. Smith
• StructureRebecca Baumez
• Command/Data HandlingSean Jones
• PowerPaul Camp Cale Johnson
• Main CommsKatherine Groenenboom
• ICSatCaleb Bauer Paul Camp
• CFTP Col. Smith
• MIDNJames Bowen
• MEMS Matt Beasley
• Launch OperationsPaul Camp
• Wrap-upCol. Smith

4
MIDSTAR OVERVIEW

• MIDSTAR1 will serve as a standard bus which will
  house several experiments. It will also collect
  data from each experiment and send the data to
  the ground station to be processed. It is the
  first in an intended line of future buses.

5
MISSION STATEMENT

• The mission of MidSTAR I is to design a
  general-purpose satellite bus capable of
  supporting a variety of space missions by easily
  accommodating a wide range of space experiments
  and instruments.  The integration of the
  experiments with the satellite bus must be
  accomplished with minimal changes to the
  satellite bus design. 

6
MISSION REQUIREMENTS

• Power 28V gt25W Avg Communications 38.4 Kbps
• Payload General Bus
• Mass lt 90.871 kg
• Attitude Control None
• Orbit 350-400 km
• Lifetime gt 1 year

7
MISSION CONCEPT

• Mission Architecture
• Single Spacecraft
• Single Ground Station
• Delta IV Launch on ESPA Ring
• Payloads
• ICSat
• Configurable Fault Tolerant Processor
• MEMS
• MIDN
• Orbit
• Altitude (average) - 462 km
• Inclination 46
• ecentricity - 0

8
MIDSTAR CONFIGURTION
CFTP
ICSAT
PC-104
EPS
COMMS
MIDN
MEMS
9
MIDSTAR Structure
10
Launch Vehicle Structural Requirements

• Right handed coordinate frame
• Origin at outer edge of attachment ring
• 120 kg maximum mass
• Center-of-gravity must be less than 20 from
  origin on X axis
• Useable volume is 24x 28x 38
• Fundamental frequency must be greater than 35 Hz
• Sustain 10.6g in axial and lateral direction with
  safety factor of 1.25

11
Payload and Subsystem Requirements

• Must carry
• Main Communications System
• ICSAT
• CFTP

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Design Choices

• Chose octagonal structure
• High surface area
• Flexibility to mount exterior antennas
• Must stay within the useable volume given
• Three interior shelves
• Allows mounting of all components
• Utilizes interior volume most efficiently

14
Description

• Material 6061-T6 Aluminum
• Five parts
• Baseplate
• L-bracket
• Panel
• Shelf
• Stringer

15
Assembly Concept

• Create five sided bottom assembly, match
  drilling holes, and rivet structure together.
  (Step 1)
• Insert interior shelves and match drill holes
  for screws.(Step 2)
• Create three sided cowling assembly, match
  drilling holes, and rivet structure together.
  (Step 3)
• Install self-locking nutplates, match drill
  screws for solar panels.
• Add inserts and mount boxes to lower and upper
  decks. (Step 4)
• Add inserts and mount boxes to three interior
  shelves. (Step 5)
• Insert interior shelves and attach with
  screws.(Step 6)
• Bolt cowling assembly. (Step 7)
• Install solar panels.

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Fasteners

• Rivet
• 1/8 diameter
• 2117-T4 aluminum alloy solid rivets
• MS 20426AD countersunk head
• MS 20470AD round head
• Nutplate
• NAS 1773
• Self-locking
• Stainless steel
• Socket head cap screws
• NAS 1352
• A-286 Stainless steel

18
Mass Budget
19
Center of Gravity Moments of Inertia
20
Finite Element Model

• Proved natural frequency is above 35 Hz
• Based on skeleton assembly of structure
• Meshed
• Lightband
• Eight side panels
• Two interior shelves
• Exterior end shelf

21
Validity Checks

• Free edge checks
• Indicate misalignment
• Indicate location of coincident nodes
• Coincident node check
• Combined or eliminated duplicates to increase
  quality of FE model
• Mass properties information
• Mass properties of mesh matched the mass
  properties of the structure

22
Boundary Conditions

• Clamped at lightband side of structure
• Simulates attachment to ESPA ring
• Other surfaces were rigidly attached to each
  other
• Simulates bolts and rivets throughout the
  structure

23
Results Mode 1

• Frequency 150.1631 Hz (lowest frequency)
• Displacement 1.93 E 01 mm
• Comments Drumming effect

24
Mode 2

• Frequency 162.846 Hz
• Displacement 2.18 E 01 mm
• Comments Cantilever beam effect

25
Mode 4

• Frequency 165.7479 Hz
• Displacement 1.93 E 01 mm
• Comments Drumming effect

26
Mode 6

• Frequency 335.3364 Hz
• Displacement 6.91 E 02 mm
• Comments Drumming effect, significantly higher
  frequency than natural frequency

27
Mode 8

• Frequency 349.5273 Hz
• Displacement 1.04 E 01 mm
• Comments Torsion

28
Mode 10

• Frequency 351.9548 Hz
• Displacement 7.24 E 02 mm
• Comments Torsion/Drumming

29
Backup Slides
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MidSTAR-1

• COMMAND AND DATA HANDLING SYSTEM

32
Command Data Handling Requirements

• 50 MHz processor
• 32 MBytes of RAM
• 50 MBytes of storage
• Synchronous Serial Ports
• Asynchronous Serial Ports
• 128 Analog Inputs
• 32 Digital Control Lines

33
Command Data Handling Implementation

• 133 MHz PowerPC processor
• 128 MBytes of ECC SDRAM
• 384 MBytes of storage
• 2 Synchronous Serial Ports
• 6 Asynchronous Serial Ports
• 128 Analog Inputs
• 56 Digital Control Lines

34
Requirements on Bus

• 5V Power
• Room for 2 10x10x4 weighing 5 kg ea.
• -40 - 80 degrees Centigrade
• 10 - 80 humidity

35
Hardware Block Diagram
36
Software Block Diagram
37
Network Flow Diagram
38
Power Budget
39
Fiscal Budget
40
MidSTAR-1

• ELECTRICAL POWER SYSTEM

41
Power System Requirements

• General Purpose Bus
• 28V gt25W Avg Power
• Have 6.5x28 available per side for solar panels
• Battery Capacity 42W-hr
• Battery charging system
• Power distribution system with
• ability to supply various voltages
• commandable switching and short-circuit
  protection

Solar World Space-Rated Cells
42
Power Flow Schematic
T/V Telemetry/Voltage T/C Telemetry/Current
43
Power Budget / Duty Cycle(Main Comms X-mit)
44
Power Budget / Duty Cycle(ICSat X-mit)
45
Design Decisions

• 2 6.5x14 panels per side 16 total
• 1 GaAs 27 efficiency
• 1 Silicon 15 efficiency
• 8 GaAs cell panels, 8 Silicon cell panels.
• 24 Sanyo NiCd cells in each battery all cells
  lined in series
• D size, 4.4A-hr
• Thermal Interface between panels and structure
• Battery board designed with PCB Express

46
Solar Panel Arrangement
Si
Si
GaAs
GaAs
GaAs
Si
47
Parts List / Budget
48
MidSTAR-1

• COMMUNICATIONS

49
Main Comms Requirements

• Accommodate experiments
• BER 2x10-5 (CFTP)
• Data rate 100 kbps (CFTP)
• Temperature -20 C to 70 C (ICSat)
• Humidity 30 to 80 (ICSat)
• Frequencies
• Uplink is 1.767 GHz
• Downlink is 2.20226 GHz
• Use NPS for back-up ground station

50
Link Budget
51
Design decisions

• 3-meter antenna dish for uplink
• SpaceQuest transmitter (TX-2400)
• 1 W transmitter, split to two antennas, for a
  total of 0.5 W transmitted power
• SpaceQuest receiver (RX-2400)
• SpaceQuest Modem (MOD-96)
• GMSK Modulation

52
Wiring Diagram
53
Power Budget

• Peak Power
• 8.83 W
• Average Power
• 4.63 W
• Duty Cycle
• 100 for receiver
• 100 for modem
• 10.7 for transmitter

54
Positioning on Shelf 2
MOD 96
RX 2400
TX 2400
55
Specifications of SpaceQuest communications
components
56
Ground Station
57
Schedule
58
Fiscal
Budget
59
Link
Budget
60
MidSTAR-1

• INTERNET COMMUNICATIONS SATELLITE

61
ICSAT Requirements

• Transmit and receive data and command files over
  a 1 Mbps link using Internet Protocols.
• PC-104 using Linux operating system
• Small (lt1kB) and large (gt1MB) files embedded on
  PC-104 or generated by onboard experiments
• Provide 15V, 12V, 5V, and ground connections
• Average Power 5.2W
• Peak Power 38W

62
ICSat Requirements (Cont.)

• Duty Cycle Receiver 10/orbit
• Transmitter 10/orbit.
• Comblock box
• 10x10x4, 3kg
• Amplifier boxes (4)
• 2 - 3x3x3 boxes, 1kg/each
• 2 - 3x2x3 boxes, 1kg/each
• Temperature Range -20oC to 70o
• Humidity 30 to 80

63
Hardware
64
Wiring Diagram - Transmit
65
Wiring Diagram - Receive
66
ICSat Component Layout
Receiver D/A Convertor
Demodulator
LineAmp
D/A Convertor
Modulator
Transmitter
67
ICSat Station 27LNA and Power Amplifier
68
Station 0LNA and Power Amplifier
69
Operations Plan
Determine if ComBlock transmitter is within
operating limits
Run diagnostics
If so, turn on ICSat transmitter
If not, do not turn transmitter on
If no ping response is received from ICSat,
retransmit ping until satisfied ICSat is not
working (max 5 tries)
Transmit ping to ICSat from SGS
Retry next orbit
If ping is received, transmit ping to SGS
Conduct File Comparison Experiment
Conduct TCP Transfer Experiment
Conduct MDP Transfer Experiment
70
Software Block Diagram
Housekeeping Routine
1
2
3
4
Test
File Comparison
TCP Transfer
MDP Transfer
Diagnostic
71
ICSat Hardware Specs
72
ComBlock Parts and Budget
Model
Description
Quantity
Unit Price
Total Price
COM-1001
BPSK DEMODULATOR
1
295.00


295.00


COM-1002
BPSK MODULATOR
1
295.00


295.00


COM-2001
DIGITAL-TO-ANALOG CONVERTOR
1
295.00


295.00


1500-1740MHz RECEIVER/
COM-3003
DIGITAL-TO-ANALOG CONVERTOR
1
345.00


345.00


COM-4001
2.0-2.5GHz TRANSMITTER
1
345.00


345.00


ZFSC-2-2500
POWER SPLITTER
1
75.00


75.00


ZFSC-2-2500
POWER COMBINER
1
75.00


75.00


ZJL-3G
LOW POWER AMPLIFIER
1
115.00


115.00


AMF-3B-020040-20-30P
POWER AMPLIFIER
2
1,500.00


3,000.00


AMF-4F-01000200-12-10P
LOW NOISE AMPLIFIER
2
1,000.00


2,000.00


Custom
ALUMINUM BOXES
3
200.00


600.00


-
WIRING
-
300.00


300.00


Total
7,740.00


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Software Block Diagram
74
Software Block Diagram (Cont.)
75
Software Block Diagram (Cont.)
76
MidSTAR-1

• CONFIGURABLE FAULT TOLERANT PROCESSOR

77
CFTP Concept

• Objective Evaluate on-orbit, a Triple Modular
  Redundant (TMR), fault-tolerant reconfigurable
  System-On-a-Chip (SOC) design to mitigate bit
  errors in computation by detecting errors and
  correcting them through voting logic.
• Utilize Commercial Off The Shelf (COTS) Field
  Programmable Gate Array (FPGA) technology
• Reduce development time and cost
• Increase reliability in hardware
• Increase flexibility and upgradeability
• Minimize power consumption

78
CFTP Architecture
79
Requirements

• 6 x 8 x 3
• 5 kg
• -40 to 85 C
• 6 W Nominal, 11 W Peak, 0.5 W Standby
• 100 duty cycle
• 28 VDC

80
MidSTAR-1

• MICRODOSIMETER INSTRUMENT

81
Mission The MIDN MIcroDosimeter iNstrument is
designed to measure the radiation spectrum with
primary emphasis on secondary neutrons with the
characteristics of being a digital, real time,
low power, low-cost, and solid state
microdosimeter.
The mission goal is to demonstrate the in-orbit
capabilities of the instrument to monitor the
trapped and temporal radiation environment and
demonstrate its potential use on the
International Space Station as a real-time
radiation monitor for astronaut safety.
82
MIDN Requirements

• MIDN Needs
• Mass 5 kg
• Power 3W Peak
• Data Storage 1Mb
• Thermal Control 0-35C

• MidStar Provides
• Allowable
• Allowable
• Allowable
• Allowable

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MidSTAR-1

• MICRO-ELECTRO-MECHANICAL STRUCTURE

85
Satellite Thermal Control

• Applied Physics Laboratory at Johns Hopkins
  University is currently producing a MEMS device
  for the thermal control of a satellite
• the vacuum of space allows the transfer of heat
  only by light radiation and not conduction or
  convection

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OFF
-
Control Voltage
Sputtered Nitride (Electrically Insulating)
Silicon in Thermal Contact with Satellite
Gold Structure with Emissive Coating
ON
-
Control Voltage
100 µm
SU-8 Polymer (Thermally Insulating)
100 µm
87
Initial Package Design
Power Supply
Communications Link
Metal (Thermally Conductive)
Electrical Insulator, Ceramic
Window (Transparent to IR/near IR Light)
Polymer (Thermal Insulator)
MEMS Device
88
Total Package and Satellite Interconnect
Bolts to Satellite Structure (4 total)
Db 25 Connector
2 in.
Power Supply
Ground
2.5 in.
Thermister Output Connection
Single Thermal Control Device
Height 1/8 in.
89
Power and Data Requirements

• Device requires power only while switching
  between the ON and OFF positions
• Each device acts as capacitor
• Power C?v?(dv/dt) P lt 1mW/device
• Energy 0.5?C?v2??t
• Data will be retrieved from 4 thermistors and
  collected/stored/transmitted with all other data
  collected

90
MidSTAR-1

• OPERATIONS PLAN

91
Run Up
92
Nominal Operations (1 Pass)

• During the orbit, the onboard computer will
  collect data from CFTP, MIDN, MEMS (how often
  will depend on each experiments requirements)
• During a pass over the NA SGS, main
  communications will transmit experimental data,
  orbit telemetry and real time telemetry
• ICSAT, when deemed reliable, will be used as main
  comms and transmit the above data

93
End of Mission Operations

• MIDSTAR-1 must be turned off permanently at
  satellites end-of-life
• A hardware command, which will be recognized by
  the onboard computer, will be transmitted by the
  USNA SGS to turn off MIDSTAR-1
• When MIDSTAR-1 turns off, all experiments will be
  turned off, the batteries will be disconnected
  from the solar panels and the batteries will be
  drained
• MIDSTAR-1 will be considered terminated

94
MidSTAR-1

• PROJECT MANAGEMENT

95
Personnel

• Electrical Power System
• Professor Luiza Sellami, EE Dept
• Payload (CFTP)
• Maj Dean Ebert, USMC, EE Dept
• Communications and Payload (ICSat)
• Ronald Parise, Computer Sciences Corp
• Structure
• Andrew Jones, NASA Goddard Space Flight Center
• Alexia Lyons, NASA Goddard Space Flight Center
• Payload (MIDN)
• Professor Vince Pisacane, Aero Dept
• Payload (MEMS)
• Professor Samara Firebaugh, EE Dept

96
Schedule

• Preliminary Design Review April 2003
• Mass Model Complete Sept 2003
• Critical Design Review Oct 2003
• Begin Construction Jan 2004
• Construction Complete Oct 2004
• Flight Certification Jan 2005
• Pre-ship Review Mar 2005
• Ship to Cape Jan 2006
• Launch Mar 2006

97
Status and Plans, 2003

• Structure
• Design Complete Finite Element Model Complete
• Assembly procedure TBD Environmental Testing TBD
• Summer 03
• Electrical Power, Comms, Command/Data Handling
• Design Complete
• Engineering Development Unit Build TBD
• Summer and Fall 03
• Payloads
• Delivery Fall 03
• Ground System
• Equipment on order
• Delivery Summer 03

98
Budget
99

• QUESTIONS AND DISCUSSION