Primary Structure Assembly Plan

1
Primary Structure Assembly Plan
2
The End State
3
Preliminaries

• MidSTAR-1 will be assembled in Rickover Hall at
  the U. S. Naval Academy using a Class 100,000
  clean room.
• The shipping container will also serve as the
  assembly platform on which the spacecraft will be
  built from the lightband up.
• 10 bolts with locking threaded inserts and
  locking nut plates will be used in this assembly.

4
Assembly Foundation

1. Mount lightband to x face of baseplate.
2. Mount lightband to shipping container interface.

5
Stringer Attachment

1. Bolt seven T-6061 aluminum stringers to the
   baseplate.

6
MidSTAR Skeleton Assembly

1. Bond floating nut plates to bored out faces of
   each shelf.
2. Sequentially lower each shelf into spacecraft
   frame, and bolt to stringers.
3. Bolt two panels to spacecraft frame along
   orthogonal axes.

At this stage of assembly, aluminum surfaces
will be cleaned in preparation
for payload/vital systems integration.
7
Baseplate Assembly

1. Bolt Battery Box A to Position 1.
2. Bolt LNA-A to Position 2.
3. Bolt Amplifier A to Position 3.

8
Bottom Shelf Assembly

1. Bolt Battery Box B to Position 4 on x face of
   shelf.

9
Middle Shelf Assembly

1. Bolt insulated MIDN payload to Position 5 on x
   face of shelf.
2. Bolt to x face of middle shelf C DH system
   (Pos. 6), FCU payload (Pos. 7), Transmitter (Pos.
   8), and Receiver (Pos. 9).

10
Top Shelf Assembly

1. Bolt to x face of top shelf ICSat (Pos. 10),
   LNA-B (Pos. 11), and Amplifier B (Pos. 12).
2. Bolt x face of top shelf MIDN sensor (Pos. 13)
   and CHEMSensor (Pos. 14).

11
Outer Deck Assembly

1. Bolt to x face of outer deck Regulator (Pos.
   15), MIDN Electronics (Pos 16), and Distributor
   (Pos. 17).
2. Bolt to x face of outer deck CFTP (Pos. 18),
   MIDN sensor (Pos. 19), MEMS (Pos. 20), and
   Eclipse (Pos. 21).

12
Final Stringer Attachment
Wiring Harness Channel

1. Bond floating nut plates to stringer.
2. Bolt remaining stringer to the spacecraft frame.
3. Integrate wiring harness into spacecraft frame.
   It should traverse the x-axis of the spacecraft
   frame and pass between shelves thru the indicated
   channel.

13
Side Panel Integration

• Bolt remaining two rigid panels to spacecraft
  frame using nuts and bolts.
• Bond/bolt solar panels to skin of spacecraft.
• Bolt remaining four panels to exterior of
  spacecraft frame.