development of a nano-satellite reaction wheel system with commercial...
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Challenge the future
DelftUniversity ofTechnology
Development of a Nano-Satellite Reaction Wheel System with Commercial Off-The-Shelf Motors
E.H. Dekens, G.F. Brouwer, J. Bouwmeester, J.M. KuiperFaculty of Aerospace Engineering, Chair of Space Systems Engineering
7th ESA Roundtable on Micro & Nano Technologies for Space Applications, 14 September 2010, ESTEC, Noordwijk, The Netherlands
Presented by G.F. Brouwer
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27th ESA Roundtable on Micro & Nano Technologies for Space Applications, 14 September 2010
Contents
• Delfi-program at TU Delft• Delfi-n3Xt key characteristics• Delfi-n3Xt satellite ADCS• Development strategies for reaction wheel• Design aspects• Development test program• Vibration tests• Conclusions• Outlook• Questions
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37th ESA Roundtable on Micro & Nano Technologies for Space Applications, 14 September 2010
Delfi-program at TU Delft
• Delfi-C3 nano-satellite launched in 2008 and a full mission success• Delfi-n3Xt nano-satellite under development for launch in 2012• Hands-on education for students in Master of Science program• Demonstration of small satellite technology for Dutch space sector• Development of advanced nano-satellite bus
Delfi-C3
Delfi-n3Xt
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47th ESA Roundtable on Micro & Nano Technologies for Space Applications, 14 September 2010
Delfi-n3Xt key characteristics
• Nano-satellite of size 340 x 100 x 100 mm• Mass about 3 kg• Power about 6.5 W• Two payloads from Dutch space sector:
• Micro-propulsion system (TNO)
• High Efficient Transceiver (ISIS)
• Experimental amorphous silicon cells (DIMES)• Advancement on all subsystems compared to Delfi-C3
• Launch planned for early 2012
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57th ESA Roundtable on Micro & Nano Technologies for Space Applications, 14 September 2010
Delfi-n3Xt satellite ADCS
• The Delfi-n3Xt Attitude Determination Control Subsystem (ADCS) should be able to maintain sun-pointing along longitudinal axis
• The following hardware is envisaged:• 6 redundant coarse sun sensors (Silonex photodiode)
• 1 fine sun sensor (TNO)
• 1 3-axis magnetometer (Honeywell HMC5843)
• 1 3-axis MEMS gyro (ST Micro-Electronics L3G4200DH)
• 3 magneto-torquers (TU Delft)
• 3 reaction wheels (TU Delft)
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67th ESA Roundtable on Micro & Nano Technologies for Space Applications, 14 September 2010
Development strategies for reaction wheel
• Three possible strategies:1. Buy Commercial Off-The-Shelf (COTS) reaction wheel
2. Develop complete reaction wheel in-house
3. Develop reaction wheel around a COTS motor
• The third strategy allows for • Low cost
• Moderate development time
• Educational experience for students
Downside: Expected lifetime is uncertain
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77th ESA Roundtable on Micro & Nano Technologies for Space Applications, 14 September 2010
Choosing the motor
• Brushless Direct Current (DC) motors offer best performance• Highest speed at which torque-level still meets mission
requirement is a comparison basis for motor performance• Ability to withstand space environment important,
but usually nearly no data available from manufacturer (especially for mechanical load resistance)
• Integrated speed controller simplifies development (customizing controller often not possible however)
• Our choice: Faulhaber 2209T005BSC motorPicture: Courtesy Faulhaber
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87th ESA Roundtable on Micro & Nano Technologies for Space Applications, 14 September 2010
Reaction wheel assembly design
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97th ESA Roundtable on Micro & Nano Technologies for Space Applications, 14 September 2010
Vacuum-proofing
• COTS motors are normally not suited for use in vacuum of space• Two solutions:
• Use hermetically sealed pressurized container
• Modify motor to make it vacuum compatible
• Manufacturer replaced lubricant in our motor with vacuum-proof lubricant (Braycote)
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107th ESA Roundtable on Micro & Nano Technologies for Space Applications, 14 September 2010
Characteristics reaction wheel system
• Maximum torque: 0.09 mNm• Angular momentum storage: 1.5·10-3 Nms• Total mass (bracket + 3 wheels) 104 gram• Max. peak power consumption: ± 400 mW
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117th ESA Roundtable on Micro & Nano Technologies for Space Applications, 14 September 2010
Development test program
• Standardized electrical performance test for motor to be used for repeated characterisation
• Vibration test campaigns• 1st : In-house vibration test at Faculty of Mechanical Engineering
• 2nd: Vibration test at NLR as passenger in ISIPOD qualification
• Thermal vacuum test (not performed yet)
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127th ESA Roundtable on Micro & Nano Technologies for Space Applications, 14 September 2010
Vibration testing
• Vibration testing is critical because of vulnerable motor axle with large unsupported mass attached
• Internal damage of motor (e.g. bearings) may cause performance degradation, but not necessarily catastrophic failure
• Steady-state current measured before and after vibration sessions• Increased steady-state current after vibration test is an indicator
of additional friction due to bearing damage
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137th ESA Roundtable on Micro & Nano Technologies for Space Applications, 14 September 2010
Standardized performance test for motor
• A standardized electrical performance test was made for the motor• Test can be run in a automatic sequence with control parameters:
• Variable voltage throughout the sequences• Duration of one sequence• Number of sequences
• Measured parameter is motor current Graph shows steady-state current consumption before and after 1st vibration test campaign. No drastic changes are seen.
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147th ESA Roundtable on Micro & Nano Technologies for Space Applications, 14 September 2010
1st
Vibration test campaign
• 1st Vibration test series at the Faculty of Mechanical, Maritime & Materials Engineering (3mE) at TU Delft
• A small shaker set-up was used
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157th ESA Roundtable on Micro & Nano Technologies for Space Applications, 14 September 2010
1st
Vibration test campaign
• Qualification loads of a Polar Satellite Launch Vehicle (India) were simulated
Frequency range (Hz) Amplitude5 – 10 10 mm10 -100 3.75 g
Sweeprate = 2 octaves/minute
Sine vibration
Random vibration
• Multiple vibration sessions were performed, (many runs needed to tune input profile to obtain required output)
• Electrical performance showed no detectable degradation• Total added up vibration time was about one hour
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167th ESA Roundtable on Micro & Nano Technologies for Space Applications, 14 September 2010
• Piggy-back vibration test in ISIPOD launch canister of ISIS B.V.• Test was done at the National Aerospace Laboratory (NLR)• Two reaction wheels and one dummy on a PCB were installed
in a 1-Unit CubeSat
2nd
Vibration test campaign
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177th ESA Roundtable on Micro & Nano Technologies for Space Applications, 14 September 2010
2nd
Vibration test campaign
0 .20 0 .90s
-35 .00
23 .00
Rea
l
g
5.00 100.00Hz
0.10
10.00
Logg
0.00
1.00
Ampl
itude
2 0 .00 2000 .00Hz
0 .01
1 .00
Log
g2/H
z
Pictures: National Aerospace Laboratory
The qualification vibration test profile was an envelope for multiple launch vehicles.
Sine-burstSine vibration
Random vibration
Test order1. Resonance survey
2. Sine Burst
3. Resonance survey
4. Sine sweep
5. Resonance survey
6. Random vibration
7. Resonance survey
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187th ESA Roundtable on Micro & Nano Technologies for Space Applications, 14 September 2010
Resonance surveys vibration campaign1st test: Y-direction
3rd test: X-direction
2nd test: Z-direction
For comparison: Resonance plot 1st vibration test. NOTE that the test configuration is not the same !
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197th ESA Roundtable on Micro & Nano Technologies for Space Applications, 14 September 2010
2nd
Vibration test campaign –
results & post test inspection
• Reaction wheel 1: Motor completely disintegrated; damage and debris was found inside the bearings (N.B. This motor has also seen test 1)
• Reaction wheel 2: Flywheel came from the motor axle; motor intact, no play on bearings found; electrically it does not run anymore
• It is suspected that the failures occurred during random vibrations
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207th ESA Roundtable on Micro & Nano Technologies for Space Applications, 14 September 2010
Conclusions
• So far the Delfi program has shown a high educational value• (Vibration) testing of custom-built hardware should be done in
an early design stage and preferably in-house• The automated electrical performance test of the motors is
a very useful tool during environmental testing• Load levels during the 2nd vibration test levels were a bridge
too far• Current reaction wheel design could survive launch on a PSLV
rocket, but the safety margin is small• The eigenfrequency measured on the bracket was below 100 Hz,
leading to large load amplifications
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217th ESA Roundtable on Micro & Nano Technologies for Space Applications, 14 September 2010
Outlook
• Development of reaction wheels for Delfi-n3Xt and successors is continuing
• The support structure around the reaction wheels should be modified to increase eigenfrequencies
• A new vibration test at more realistic load levels should be performed
• The desire is to upgrade the existing vibration testing facility at TU Delft to allow testing of higher masses with better control of load levels
• Thermal-vacuum testing will be performed after completion of a successful vibration test
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227th ESA Roundtable on Micro & Nano Technologies for Space Applications, 14 September 2010
Acknowledgements
• Faculty of 3mE at Delft University of TechnologyProf. Dr. D.J. Rixen and M. Ozbek MSc for their extensive support with the 1st vibration test
• Innovative Solutions in Space BV (ISIS B.V.)Mr. G. Lebbink for enabling and supporting the vibration test in an ISIPOD.
• National Aerospace Laboratory (NLR) for their support with 2nd vibration test
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237th ESA Roundtable on Micro & Nano Technologies for Space Applications, 14 September 2010
Questions?
Delfi-n3Xt Engineering Model Structure in integration jig