The whole Cubesat functionality depends on the integrity of its subsystems. For that reason, it is very important that the structure subsystem is built to be robust and reliable to ensure the protection of all other subsystems integrated within.
The goal is to develop a high performance Cubesat structure with the use of new materials, like composite materials. The use of composite materials for primary structure increases the strength and reduces the weight of existing Cubesat structures increasing at the same time the payload capacity.
Interplanetary missions require more robust and reliable structures so a Cubesat manufactured with composite materials could be the solution for those exploratory missions. One of the keys of a composite structure is the design in order to reduce manufacturing cost and stress concentration, especially on interference with other components.
The results of study on alternative structures designs for Cubesat, shows that one solid wall composite Cubesat design can stand up to 25g loads with a temperature range of -55°C (-67° F) to 90°C (194° F). Additionally, the vibration simulation results show a minimum vibration mode of 157.6 Hz. All of that was achieved with a weight of 183 grams.
Table of Contents
Chapter 1. Introduction
1.1 CubeSat missions
1.1.1 Poly Picosatellite Orbital Deployer (P-POD)
1.1.2 CubeSat
1.2 Project objectives
Chapter 2. Background
2.1 Missions
2.1.1 NASA Missions
2.1.2 ESA Missions
2.2 Structures
2.2.1 Kit CubeSat Structures
2.2.2 Custom Made CubeSat Structures
2.3 Requirements
2.3.1 Analysis Requirements
Chapter 3. Alternative Cubesat structure
3.1 Introduction and Background
3.2 Additional requirements
3.3 Materials
3.3.1 Metallic materials
3.3.2 Nonmetallic materials
3.3.3 Material evaluation
3.4 Manufacture processes
3.4.1 Metallic Materials:
3.4.2 Non-Metallic Materials
3.4.3 Joint Methods
3.5 Conceptual Study
3.6 Design Concept
3.6.1 Internal Columns
3.6.2 Shear panels
3.6.3 Shear angles
3.6.4 Rails
3.6.5 Feet Blocks
3.6.6 Assembly process
3.6.7 Payload interface
3.7 Finite Element Model
3.7.1 Finite element validation
3.7.2 Load Cases
3.7.3 Static Analysis
3.7.4 Vibration Analysis
3.8 Summary Results
Chapter 4. Conclusions and Future works
Project Objective and Thematic Focus
The primary objective of this project is to design a high-performance 1U CubeSat structure using innovative materials like composites to improve strength and payload capacity while minimizing weight and manufacturing costs. The research focuses on establishing a baseline design that meets Cal Poly and NASA standards, ensuring the structural integrity of the satellite during the extreme conditions of launch and operation.
- Development of a lightweight, multi-configurable composite structure for 1U CubeSats.
- Comparative material analysis focusing on strength, thermal stability, and outgassing properties.
- Integration of advanced manufacturing processes, including CNC machining and composite assembly.
- Comprehensive structural analysis using Finite Element Modeling (FEM) to evaluate static loads and vibrations.
- Creation of a high-performance attachment system to protect internal electronic components from structural stress.
Excerpt from the Book
3.6.7 Payload interface
The main purpose of the structure subsystem is protecting the other subsystems and the main payload or mission. The subsystems interface with the structure is thru the internal columns. The columns are designed to be customized attachment of any subsystem and to protect the cargo from any load or external impact. Acceleration load cannot be avoided but external loads can.
The important of the structure is not applied any load or deflection into the circuit boards and component that can be a hazard. Because of this reason a maximum 0.5 mm displacement in the internal columns is imposed as additional requirement. There are two types of attachment to the structure.
Summary of Chapters
Chapter 1. Introduction: Outlines the origins of the CubeSat program, its primary mission goals, and the specific objectives for this structural design project.
Chapter 2. Background: Provides an overview of existing CubeSat missions sponsored by NASA and ESA, along with an analysis of current structural trends and requirements.
Chapter 3. Alternative Cubesat structure: Details the development of a new structure concept, covering material evaluation, manufacturing processes, design concepts, and extensive validation through Finite Element Modeling.
Chapter 4. Conclusions and Future works: Summarizes the project's success in developing a robust structural solution and outlines necessary future steps, such as prototype fabrication and testing.
Keywords
CubeSat, Structural Design, Composite Materials, Finite Element Analysis, Satellite Engineering, Aerospace Structures, Mechanical Loads, Vibration Analysis, 1U Configuration, Material Selection, Manufacturing Processes, Lightweight Structures, Payload Protection, Structural Integrity, Static Loads
Frequently Asked Questions
What is the core focus of this project?
The project focuses on developing a high-performance, lightweight 1U CubeSat structure using composite materials to improve strength and increase payload capacity compared to traditional designs.
What are the primary themes addressed?
The study covers mission background, material selection, advanced manufacturing techniques, structural configuration, and rigorous validation through Finite Element Analysis.
What is the research goal?
The goal is to design an alternative, cost-effective structure that exceeds existing standards for load handling and protection while meeting all mission-critical requirements.
Which scientific methods were applied?
The project utilizes structural engineering principles, material science evaluation, and Finite Element Modeling (FEM) to simulate static and dynamic loads on the CubeSat.
What does the main body cover?
It details the design of internal columns, shear panels, rails, and assembly processes, alongside a comprehensive simulation of stress and vibration behavior.
Which keywords best describe this research?
Key terms include CubeSat, structural design, composite materials, finite element analysis, and aerospace structural engineering.
How is the payload protected in this design?
The design incorporates a "high performance attachment" (HPA) system that supports circuit boards while isolating them from the structural loads and deformations occurring during launch.
What was the result of the structural simulation?
The simulation proved that the solid-wall composite design could withstand up to 25g of load within a specific temperature range, while maintaining a weight of only 183 grams.
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- Gustavo Cotta Vallina (Autor:in), 2014, Alternative structure design for Cubesat, München, GRIN Verlag, https://www.grin.com/document/284992
