The document discusses the conceptual design review for the structural design of the Aeolus satellite. The engineering team identifies key requirements from customers as performance, low cost, compatibility, reliability, low density, and availability. They propose a final concept of an aluminum 6061 isogrid structure with dimensions of 100mm x 113.5mm and a structural mass of less than 400 grams. A budget of 38,00,000 INR over 6 months is estimated for the design, manufacturing, and testing of the cube satellite bus structure.
The document discusses the conceptual design review for the structural design of the Aeolus satellite. The engineering team identifies key requirements from customers as performance, low cost, compatibility, reliability, low density, and availability. They propose a final concept of an aluminum 6061 isogrid structure with dimensions of 100mm x 113.5mm and a structural mass of less than 400 grams. A budget of 38,00,000 INR over 6 months is estimated for the design, manufacturing, and testing of the cube satellite bus structure.
The document discusses the conceptual design review for the structural design of the Aeolus satellite. The engineering team identifies key requirements from customers as performance, low cost, compatibility, reliability, low density, and availability. They propose a final concept of an aluminum 6061 isogrid structure with dimensions of 100mm x 113.5mm and a structural mass of less than 400 grams. A budget of 38,00,000 INR over 6 months is estimated for the design, manufacturing, and testing of the cube satellite bus structure.
Engineering team: Raja Guru Suresh Muthaiah Sundarvathanan Rakesh Gunasekear
Design Objective
Cube sat Need CTQ Technical cost Structural integrity Mass Availability Carry sub systems Low cost
Compatibility Low density
Manufacturing time VOC Driving parameters From the customer through VOC following are the needs identified;
Performance Low cost Compatibility Reliability Low density Availability Above mentioned are the identified requirements from the customers for this review.
Challenges, solutions and advantages
Challenges: Shorter working life Less pay loads Power constraints Lower transmitter output capacity Redundancy only for critical systems Rapid orbital decay
Solution: Advancement in small satellite technology!! Advantages of solutions: Rapid expansion of technology Diverse potential users since we could achieve various mission agendas More frequent missions Opportunities for research activities
1U satellite requirements Operational requirements Accommodate payload systems for LEO missions Able to accommodate as a piggy back option. Capable of operating in LEO orbits Ability to withstand loads during various mission phase. Accommodate all deployable for LEO missions Accommodate sub systems for LEO missions(as per mission)
Performance requirements Holds the payload as an integral unit Satisfy the PSLV interface design requirements Capable to transmit required communication Withstand launch loads, thermal loads, perturbations, and yet flexible Accommodate booms, antennas, solar panels Accommodate sub systems as given by the cube sate design specification
Payload systems & applications Scientific research Technology demonstration Earth observation Telecommunications Low cost launchers Military applications Academic training
Design configuration Size 100mm ( 0.1mm) Height 113.5mm (0.1mm) Stacked, slots Mass 1.33 kg (dry)
As per cube satellite design specification
Final Proposed Concept:
Aluminum 6061 : High strength, light-weight, easy machinability, and cost Isogrid: Low mass and high strength Size 100mm ( 0.1mm), Height 113.5mm (0.1mm) Structural Mass: < 400 grams AL-6061-T6 320 MPa 2850 kg/m3 Easy $15.00 AL-7075-T6 340 MPa 2796 kg/m3 Easy $30.38 Structure configuration Competitors Cubesat shop Clyde space Cubesat kit ISIS Gomspace Stras space
Name Space proven Dry mass(grams) thermal range C Material Cube satkit P 300 (-) 40 to 85 degree Alumininium ISIS P <400 (-) 50 to 90 degree Alumininium Clydespace P 300 (-) 40 to 85 degree Alumininium Gomspace P 725 Alumininium Gantt chart Gantt chart Feb March April May June
Design study Conceptual design review Preliminary design review Critical design review Final design approval Procurement Proto type manufacturing validation and testing
Fabricate structure Testing Temperature distribution Spacecraft dynamic model Coupled load analysis Dynamic response(iterative) Preliminary launch loads Thermal analysis Budget Direct cost Estimated period Salary Specific material Transport Sub contract Indirect cost Employee benefits Office rent Equipements Analysis tools Administrative cost Cost estimate
Budget *Project schedule 6 months Engineering members 4
Direct cost INR Engineer salary 400000 Material ( 2mm sheet) 2000 Transport 10000 Subcontract(40%) 800000 Indirect cost INR Office rent(6 months) 100000 Equipments 100000 Analysis tools 2000000 Administrative cost 20000 Employee benefits(5%)10000 20000 Total 3452000
Output: Approximate budget to design and manufacture cube satellite bus ( with 10% extra) would be 38,00,000 INR. Fund required for ISRO validation, testing after 4 months from kick off
Seek Medical Adviser . Consult with the supervisor if becomes more serious
Lack of MSC Patron skills & Knowledge at initial stages
Med
Med
More background reading. Also Seek advice from the expert Lack of knowledge of Vibration analysis. And Launch load analysis High
High Read up on previous examples or on similar techniques. Require Experience stress Engineer And Also Seek advice from the expert.
Lack of knowledge of thermal analysis and space thermal environment
High High Read up on previous examples or on similar techniques , software training (MSC software /NX ) ,and Seek advice from the ISRO expert External changes to the project
High High Continuous meetings with ISRO scientist (Advice) and all the other groups working on the project to ensure any changes are anticipated and dealt with in sufficient time
Changes to the CubeSat design
High
Med
Tie in with Cube Sat design team to ensure that the Design change
Workshop & Manufacturing Delays
High
High Try to submit the drawing as early as possible .Identify alternative manufacturing facilities. Malfunctioning of the Cube sat system
Med High Verify the design concept & check the final drawing with design validation team and Workshop Technicians prior to submission
Loss of Data
Low High Ensure a proper backing-up strategy is in place. Trying to back up in various places the University file store, and Online
Experimental Testing Delays High High Identify alternative Testing facilities.