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MIDSTAR. MIDSTAR TEAM. Caleb Bauer Rebecca Baumez Ethan Biter Paul Camp Katherine Groenenboom Cale Johnson Sean Jones Kevin Yost. AGENDA. Introduction—Col. Smith Structure—Rebecca Baumez Command/Data Handling—Sean Jones Power—Paul Camp & Cale Johnson Main Comms—Katherine Groenenboom

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MIDSTAR


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midstar team
MIDSTAR TEAM
  • Caleb Bauer
  • Rebecca Baumez
  • Ethan Biter
  • Paul Camp
  • Katherine Groenenboom
  • Cale Johnson
  • Sean Jones
  • Kevin Yost
agenda
AGENDA
  • Introduction—Col. Smith
  • Structure—Rebecca Baumez
  • Command/Data Handling—Sean Jones
  • Power—Paul Camp & Cale Johnson
  • Main Comms—Katherine Groenenboom
  • ICSat—Caleb Bauer & Paul Camp
  • CFTP —Col. Smith
  • MIDN—James Bowen
  • MEMS — Matt Beasley
  • Launch Operations—Paul Camp
  • Wrap-up—Col. Smith
midstar overview
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.
mission statement
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. 
mission requirements
MISSION REQUIREMENTS
  • Power 28V; >25W Avg Communications 38.4 Kbps
  • Payload General Bus
  • Mass < 90.871 kg
  • Attitude & Control None
  • Orbit 350-400 km
  • Lifetime > 1 year
mission concept
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
midstar configurtion
MIDSTAR CONFIGURTION

CFTP

ICSAT

PC-104

EPS

COMMS

MIDN

MEMS

launch vehicle structural requirements
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 24”x 28”x 38”
  • Fundamental frequency must be greater than 35 Hz
  • Sustain 10.6g in axial and lateral direction with safety factor of 1.25
payload and subsystem requirements
Payload and Subsystem Requirements
  • Must carry:
    • Main Communications System
    • ICSAT
    • CFTP
design choices
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
description
Description
  • Material: 6061-T6 Aluminum
  • Five parts:
    • Baseplate
    • L-bracket
    • Panel
    • Shelf
    • Stringer
assembly concept
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.
fasteners
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
finite element model
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
validity checks
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
boundary conditions
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
results mode 1
Results: Mode 1
  • Frequency: 150.1631 Hz (lowest frequency)
  • Displacement: 1.93 E –01 mm
  • Comments: Drumming effect
mode 2
Mode 2
  • Frequency: 162.846 Hz
  • Displacement: 2.18 E –01 mm
  • Comments: Cantilever beam effect
mode 4
Mode 4
  • Frequency: 165.7479 Hz
  • Displacement: 1.93 E –01 mm
  • Comments: Drumming effect
mode 6
Mode 6
  • Frequency: 335.3364 Hz
  • Displacement: 6.91 E –02 mm
  • Comments: Drumming effect, significantly higher frequency than natural frequency
mode 8
Mode 8
  • Frequency: 349.5273 Hz
  • Displacement: 1.04 E –01 mm
  • Comments: Torsion
mode 10
Mode 10
  • Frequency: 351.9548 Hz
  • Displacement: 7.24 E –02 mm
  • Comments: Torsion/Drumming
midstar 1
MidSTAR-1

COMMAND AND DATA HANDLING SYSTEM

command data handling requirements
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
command data handling implementation
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
requirements on bus
Requirements on Bus
  • 5V Power
  • Room for 2 10”x10”x4” weighing 5 kg ea.
  • -40 - + 80 degrees Centigrade
  • 10% - 80% humidity
midstar 140
MidSTAR-1

ELECTRICAL POWER SYSTEM

power system requirements
Power System Requirements
  • General Purpose Bus
  • 28V; >25W Avg Power
  • Have 6.5”x28” 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

power flow schematic
Power Flow Schematic

T/V: Telemetry/Voltage

T/C: Telemetry/Current

design decisions
Design Decisions
  • 2 6.5”x14” 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
solar panel arrangement

Solar Panel Arrangement

Si

Si

GaAs

GaAs

GaAs

Si

midstar 148
MidSTAR-1

COMMUNICATIONS

main comms requirements
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
design decisions51
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
power budget53
Power Budget
  • Peak Power
  • 8.83 W
  • Average Power:
  • 4.63 W
  • Duty Cycle:
  • 100% for receiver
  • 100 % for modem
  • 10.7% for transmitter
positioning on shelf 2
Positioning on Shelf 2

MOD 96

RX 2400

TX 2400

slide58

Fiscal

Budget

slide59

Link

Budget

midstar 160
MidSTAR-1

INTERNET COMMUNICATIONS SATELLITE

icsat requirements
ICSAT Requirements
  • Transmit and receive data and command files over a 1 Mbps link using Internet Protocols.
    • PC-104 using Linux operating system
    • Small (<1kB) and large (>1MB) files embedded on PC-104 or generated by onboard experiments
  • Provide +15V, +12V, +5V, and ground connections
  • Average Power: 5.2W
  • Peak Power: 38W
icsat requirements cont
ICSat Requirements (Cont.)
  • Duty Cycle: Receiver = 10%/orbit

Transmitter = 10%/orbit.

  • Comblock box:
    • 10”x10”x4”, 3kg
  • Amplifier boxes (4):
    • 2 - 3”x3”x3” boxes, 1kg/each
    • 2 - 3”x2”x3” boxes, 1kg/each
  • Temperature Range: -20oC to 70o
  • Humidity: 30% to 80%
icsat component layout

Power Combiner

Power Splitter

ICSat Component Layout

Receiver; D/A Convertor

Demodulator

LineAmp

D/A Convertor

Modulator

Transmitter

slide69

OperationsPlan

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

software block diagram70
Software Block Diagram

Housekeeping Routine

1

3

4

2

Test

File Comparison

TCP Transfer

MDP Transfer

Diagnostic

comblock parts and budget
ComBlock Parts and Budget

Model #

Description

Quantity

Unit Price

Total Price

BPSK DEMODULATOR

COM-1001

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/

DIGITAL-TO-ANALOG CONVERTOR

COM-3003

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

software block diagram73

Collect telemetry from CBT; determine if CBT is within operational limits*

Call and run test

text.exe is not successful: call and run diagnosecicsat.exe

test is successful

Save results as diagnosticicsat.txt; transmit to SGS over Main Comms

Call midstarlogo.jpg; send to SGS through CBT

File Comparison Experiment

Receive midstarlogo1.jpg from SGS; save to memory

Call midstarlogo1.jpg; send to SGS through CBT

*Telemetry collection and evaluation will occur before every experiment

- CBT: ComBlock Transmitter

- SGS: Satellite Ground Station

Software Block Diagram
software block diagram cont

Call phrase.txt; package in TCP format

Send to SGS through CBT as many times as possible in a single pass

Save link speed over entire pass (>1sample/s) as tcpexplss.txt

TCP Transfer Experiment

Save number of times the file was sent as tcpsent.txt

Send tcpexplss.txt and tcpsent.txt to SGS through CBT

Call bigfile.txt; package in TCP format

Send bigfile.txt to SGS through CBT once

*Telemetry collection and evaluation will occur before every experiment

- CBT: ComBlock Transmitter

- SGS: Satellite Ground Station

Save link speed over entire pass (>1sample/s) as tcpexplsl.txt; send to SGS through CBT

Software Block Diagram (Cont.)
software block diagram cont75

Call phrase.txt; package in MDP format

Send to SGS through CBT as many times as possible in a single pass

Save link speed over entire pass (>1sample/s) as mdpexplss.txt

MDP Transfer Experiment

Save number of times the file was sent as mdpsent.txt

Send mdpexplss.txt and mdpsent.txt to SGS through CBT

Call bigfile.txt; package in TCP format

Send bigfile.txt to SGS through CBT once

*Telemetry collection and evaluation will occur before every experiment

- CBT: ComBlock Transmitter

- SGS: Satellite Ground Station

Save link speed over entire pass (>1sample/s) as mdpexplsl.txt; send to SGS through CBT

Software Block Diagram (Cont.)
midstar 176
MidSTAR-1

CONFIGURABLE FAULT TOLERANT PROCESSOR

cftp concept
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
cftp architecture

MEM

CNTL

FLASH

ROM

Configuration

PROM

EEPROM

Memory

FPGA

Error

Interrupt

Clock Control

PMemory Control

P

EDAC

P

voter

7.3 in

TMR PRLOS

P

Status & I/O

Interface/switching logic

RLOS

Bus Transceivers

5.3 in

CFTP Architecture
requirements
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
midstar 180
MidSTAR-1

MICRODOSIMETER INSTRUMENT

slide81

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.

midn requirements
MIDN Needs

Mass: ~5 kg

Power: 3W Peak

Data Storage: ~1Mb

Thermal Control: 0-35C

MidStar Provides

Allowable

Allowable

Allowable

Allowable

MIDN Requirements
midstar 184
MidSTAR-1

MICRO-ELECTRO-MECHANICAL STRUCTURE

satellite thermal control

Radiated Light

Vacuum and Polymer (Thermally Insulating)

OFF

ON

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
slide86

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

slide87

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

total package and satellite interconnect
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.

power and data requirements
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 < 1mW/device
      • Energy = 0.5·C·v2·Δt
  • Data will be retrieved from 4 thermistors and collected/stored/transmitted with all other data collected
midstar 190
MidSTAR-1

OPERATIONS PLAN

run up

Rocket Triggers Lightband

System

Deadman switch activates timer

of “X” Seconds

After “X” Seconds, engage

main bus

Turn on PC-104

Verify Main bus  (power

Distribution system)

Command from PC-104 will

turn on Comms

3 orbits to verify that Comms is

operating properly

If comms is working properly,a

command will turn on CFTP

Do self-diagnostic and establish

Ground comms

If comms is not working,

ICSAT will be turned on and be

used as main comms

Turn on ICSAT

Complete 3 orbits before

turning on MIDN

Do self diagnostic of CFTP and

verify results

Verify ICSAT works by

comparing with main comms

Do self diagnostic of MIDN and

verify results

Complete 3 orbits before

turning on MEMS

Once all experiments are up and

running, normal operating

procedures will take over

Run Up
nominal operations 1 pass
Nominal Operations (1 Pass)
  • During the orbit, the onboard computer will collect data from CFTP, MIDN, MEMS (how often will depend on each experiment’s 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
end of mission operations
End of Mission Operations
  • MIDSTAR-1 must be turned off permanently at satellite’s 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
midstar 194
MidSTAR-1

PROJECT MANAGEMENT

personnel
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
schedule
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
status and plans 2003
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