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Satellite Design Course

Spacecraft Configuration Structural Design


Preliminary Design Methods

Feb 16 2005

ENAE 691

R.Farley NASA/GSFC

Contents
Origin of structural requirements Spacecraft configuration examples Structural configuration examples General arrangement drawings Launch vehicle interfaces and volumes Structural materials Subsystem mass estimation techniques Vibration primmer Developing limit loads for structural design Sizing the primary structure Structural subsystem mass
pg 3 pg 8 pg 14 pg 25 pg 30 pg 33 pg 38 pg 51 pg 59 pg 68 pg 73

Feb 16 2005

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Origin of Structural Requirements


This ride not recommended for children

Launch Vehicle
3

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Source of Launch Vehicle Loads

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Typical Loads Time-Line Profile


Max Q H2 vehicle to geo-transfer orbit

MECO SECO

1st stage

2nd stage

3rd stage

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Design Requirements, Function


Launch Vehicle volume, mass, and c.g. Foot print for subsystems Deployment of flexible structures Natural frequency, stowed and deployed Alignment stability (launch shift, thermal, vibration, material shrinkage) Field Of View (FOV) RF and magnetic compatibility Jitter disturbance response Thermal steady state and transient distortions Materials for space environment (out gassing, atomic oxygen)

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Design Requirements, Loads


Testing Transportation Launch loads
Steady state accelerations (axial thrust) Steady vibrations (low frequency, resonant burn from solid rocket boosters) Transient vibrations (lift off, transonic, MECO, SECO) Acoustic and random accelerations (lift off, max Q leading to max lateral loads) Shock (payload separation from upper stage adapter) Depressurization (influence on enclosed volumes including blankets inside of instruments)

Orbit Loads

spin-up, de-spin, thermal, deployments, maneuvers

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From the spacecrafts point of view


Fixed solar array Articulating solar array, sometimes 2 axis

Articulating solar array, one axis

The sun in the orbit plane changes due to the seasonal change in the suns declination (the tilt in the Earths axis) and orbit plane precession due to the Earths equatorial bulge. At 35o inclination, the precession period is ~ 55 days
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Spacecraft Configuration Examples

EOS aqua

one oar in the water produces an aerodynamic torque that averages to zero per orbit, but reaction wheels must be large enough to absorb in the interim
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LEO nadir pointing

Configuration Types LEO stellar pointing


Low inclination XTE, HST High inclination WIRE

Articulated solar array


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Fixed solar array sun-sync orbit


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Configuration Types GEO nadir pointing


Intelsat V

TDRSS A
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Articulated s/a spin once per 24 hours


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Configuration Types HEO

IMAGE 2000

AXAF-1 CHANDRA required to stare uninterrupted

250m long wire booms, rpm


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Configuration types misc

Sun shield

MAP at L2
Sky surveys in the ecliptic plane

Cylindrical, body-mounted solar array

Lunar Prospector
Body-mounted s/a

Cassini to Saturn
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Structural Configuration Examples


Cylinders and Cones Box structures Triangle structures Rings

high buckling resistance

hanging electronics and equipment sometimes needed

transition structures and interfaces extending a hard point (picking up point loads)

Trusses

As much as possible, payload connections should be kinematic Skin Frame, Honeycomb Panels, Machined Panels, Extrusions

NOTE: ALWAYS PROVIDE A STIFF AND DIRECT LOAD PATH! AVOID BENDING! STRUCTURAL JOINTS ARE BEST IN SHEAR!

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Structural examples

MAGELLAN box, ring, truss

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Structural examples

HESSI ring, truss and deck


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OAO cylinder/stringer and decks


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Structural examples

Hybrid one of everything


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Archetypical cylinder and box


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Egg crate torque box composite panel bus structure

Structural examples
EOS aqua, bus

Hard points created at intersections


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Structural examples
COBE STS version 5000 kg ! COBE Delta II version

2171 kg !

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Structural examples
TRIANA L1 orbit

Boxes mounted to outer panels to radiate heat


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Anatomy of s/c
Axial viewing, telescope type
Interface isolation Reaction structure wheels

Astronomy Mission
Station-keeping hydrazine, polar mount Solid kick motor, equatorial mount

Kinematic Flexure mounts to remove enforced displacement loads

Instrument module Launch Vehicle adapter

Deck-mounted or wall-mounted boxes

Bus module

Propulsion module

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Modular Assembly
Instrument Module optics, detector Bus Module (house keeping) Propulsion Module Modules allow separate organizations, procurements, building and testing schedules. It all comes together at observatory integration and test (I&T) AXAF

Interface control between modules is very important: structural, electrical, thermal


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Attaching distortion-sensitive components


3,2,1 3 2
Note: vee points towards cone

Bi-pod legs, tangential flexures Breathes from center point

Ball-in-cone, Ball-in-vee, Ball on flat Breathes from point 3

2,2,2
Hexapod arrangement

JPL perfect joint for GALEX primary mirror

1,1,1,1,1,1 1 3 2
Rod flexures arranged in 3,2,1 Breathes from point 3
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General Arrangement Drawings


Stowed configuration in Launch Vehicle Transition orbit configuration Final on-station deployed configuration
Include Field of View (FOV) for instruments and thermal radiators, and communication antennas, and attitude control sensors

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3-view layout, on-orbit configuration


Overall dimensions and field of views (FOV) Antennas showing field of regard (FOR)

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3-view layout, launch configuration


Solar array panels array drive

Star trackers Torquer bars

Payload Adapter Fitting (PAF)

Make note of protrusions into payload envelope

Omni antennas
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High gain antenna, stowed 26

Launch Vehicle Interfaces and Volumes


Payload Fairings

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Pegasus Interface

Coupled loads analysis necessary


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Payload Envelope
For many vehicles, if the spacecraft meets minimum lateral frequency requirements, then the static envelope accounts for fairing dynamic motions.
STATIC ENVELOPE; the space that the
payload must fit inside of when integrated to the vehicle

DYNAMIC ENVELOPE; the space that


the payload must stay in during launch to account for all payload deflections

If frequency requirements are not met, or for protrusions outside the designated envelope, Coupled Loads Analysis (CLA) are required to qualify the design, in cooperation with the LV engineers.

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Launch Vehicle Payload Adapters


V-band clamp, or Marmon clamp-band
Shear Lip

Clamp-band

6019 3-point adapter

6915 4-point adapter

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Structural Materials
Material
Aluminum 6061-T6 7075-T651 Magnesium AZ31B Titanium 6Al-4V Beryllium S 65 A S R 200E Ferrous INVAR 36 AM 350 304L annealed 4130 steel Heat resistant
Non-magnetic

Metallic Guide
(m/m K)

(kg/m3) 2800 2700 1700 4400 2000 8082 7700 7800 7833

E (GPa) 68 71 45 110 304 150 200 193 200

Fty (MPa) 276 503 220 825 207 345 620 1034 170 1123

E/

Fty/

(W/m K)

24 26 26 25 151 18.5 26 25 25

98.6 186.3 129.4 187.5 103.5 76.7 134.3 21.8 143

23.6 23.4 26 9 11.5 1.66 11.9 17.2 12.5

167 130 79 7.5 170

14 40-60 16 48

A286 Inconel 600 Inconel 718


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7944 8414 8220

200 206 203

585 206 1034


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25 24 25

73.6 24.5 125.7

16.4 23.0

12 12 31

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Materials Guide Definitions


E Fty E/ Fty / mass density, kg/m3 Youngs modulus, Pascals material allowable yield strength Note: Pa = Pascal = N/m2

specific stiffness, the ratio of stiffness to density specific strength, the ratio of strength to density coefficient of thermal expansion CTE coefficient of thermal conductivity

Material Usage Conclusions: USE ALUMINUM WHEN YOU CAN!!!


Aluminum 7075 and Titanium 6Al-4V have the greatest strength to mass ratio Beryllium has the greatest stiffness to mass ratio and high damping 4130 Steel has the greatest yield strength
(expensive, toxic to machine, brittle)

INVAR has the lowest coefficient of thermal expansion, but difficult to process Titanium has the lowest thermal conductivity, good for metallic isolators
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Metallic Materials Usage Guide


Advantages Disadvantages

Applications

Aluminum

High strength to weight, good machining, low cost and available

Poor galling resistance, high CTE

Truss structure, skins, stringers, brackets, face sheets

Titanium

High strength to weight, low CTE, low thermal conductivity, good at high temperatures

Expensive, difficult to machine

Attach fittings for composites, thermal isolators, flexures

Steel

High stiffness, strength, low cost, weldable

Heavy, magnetic, oxidizes if not stainless steel. Stainless galls easily Heavy, difficult to machine

Fasteners, threaded parts, bearings and gears

Heat-resistant Steel

High stiffness, strength at high temperatures, oxidation resistance and non-magnetic

Fasteners, high temperature parts

Beryllium
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Very high stiffness to weight, low CTE


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Expensive, brittle, toxic to machine


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Mirrors, stiffness critical parts


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Subsystem Mass Estimation Techniques


Preliminary Design Estimates for Instrument Mass Approximate instrument mass densities, kg / m3 Spectrometers ~ Mass spectrometers ~ 250 800

Synthetic aperture radar ~ 32 Rain radars ~ Cameras ~ Small instruments ~ 150 500 1000 thickness / diameter ~ 0.2 Small telescopes w/ camera ~ 325

Scaling Laws: If a smaller instrument exists as a model, then if SF is the linear dimension scale factor Area proportional to SF2 Mass proportional to Stress proportional to SF
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SF3

Area inertia proportional to SF4 Frequency proportional to 1/ SF

Mass inertia proportional to SF5

BEWARE THE SQUARE-CUBE LAW! STRESS WILL INCREASE WITH SF!


Feb 16 2005 ENAE 691 R.Farley NASA/GSFC

Typical List of Boxes, Bus Components


ACS Reaction wheels Torquer bars Nutation damper Star trackers Inertial reference unit Earth scanner Digital sun sensor Coarse sun sensor Magnetometer ACE electrical box Mechanical Primary structure Deployment mechanisms Fittings, brackets, struts, equipment decks, cowling, hardware Payload Adapter Fitting
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Communication S-band omni antenna S-band transponder X-band omni antenna X-band transmitter Parabolic dish reflector 2-axis gimbal Gimbal electronics Diplexers, RF switches Band reject filters Coaxial cable Thermal Radiators Louvers Heat pipes Blankets Heaters Heat straps Sun shield Cryogenic pumps Cryostats
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Power Batteries Solar array panels Articulation mechanisms Articulation electronics Array diode box Shunt dissipaters Power Supply Elec. Battery a/c ducting Propulsion Propulsion tanks Pressurant tanks Thrusters Pressure sensors Filters Fill / drain valve Isolator valves Tubing
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Electrical C&DH box Wire harness Instrument electronics Instrument harness


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Mass Estimation, mass fractions Mi/Mdry


Some Typical Mass Fractions for Preliminary Design
Payload LEO nadir (GPM) LEO stellar (COBE) GEO nadir (DSP 15) LEO (Pegasus class) nadir (FireSat) 37 % Structure 24 % Power 13 % Fixed arrays 12 % spins at 1 rpm 20 % spins at 6 rpm 17 % Articulat ing arrays Electrical harness 7% ACS 6% Thermal 4% C&DH 1% Comm 3% Propulsion, dry 5% 26 % w/fuel 0%

52 %

14 %

8%

8%

2%

3%

1%

37 %

22 %

7%

6%

0.5 %

2%

2%

2%

13-20 %

30 %

7%

14 %

1%

3%

15 % 2-axis gimball

0%

Mass fractions as percentage of total spacecraft observatory mass, less fuel COBE with 52% payload fraction is unusually high and not representative
ACS is Attitude Control System, C&DH is Command and Data Handling, Comm is Communication subsystem
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Mass Estimation, Refinements


The largest contributors to mass are (neglecting the instrument payload)

Structural subsystem (primary, secondary) Propulsion fuel mass, if required Power subsystem Define ratio mi = Mi / Mdry
Mdry = mass of spacecraft less fuel Remember to target a mass margin of ~20% when compared to the throw weight of the launch vehicle and payload adapter capability. There must be room for growth, because evolving from the cartoon to the hardware, it always grows! The following slides will show the cheat-sheet for making preliminary estimates on some of these subsystems
Feb 16 2005 ENAE 691 R.Farley NASA/GSFC

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Mass Estimation with Mass Ratios


Mdry = Mpayload + Mpower + MPropDry + Mstruct + Melec + MCDH + MACS + Mcomm + Mtherm Dry mass = sum of subsystem masses without fuel 1st GUESS

mpayload ~ 0.4(large sat) ~0.2(small sat) for a first guess ratio Mdry = Mpayload / mpayload
2nd GUESS Mdry = Mpayload + Mdry(mpower+ mPropDry + mstruct + melec + mCDH + mACS + mcomm + mtherm)

3rd GUESS, more refined Mdry = Mpayload + Mpower+ MPropDry + Mdry (mstruct + melec + mCDH + mACS + mcomm + mtherm)

Mwet = Mdry + Mfuel


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Total wet mass, observatory mass Mlaunch = Mwet + payload adapter fitting Launch mass
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Mass Ratios, Generalized Formula


Mi M dry = 1 unknown known mj Generalized Formula
Sum of known masses / (1-sum of unknown masses as ratios)

Mi known

M payload

M power

M PropDry

Typical knowns + calculated

mj = unknown
+

m structure m ACS

m elec

m CDH m therm
Typical unknowns

m comm

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Mass Estimation example


Low Earth Orbit Earth-Observing Mission Known or calculated masses: Mpayload = 750 kg Mpower = 200 kg MPropDry = 40 kg Will use these ratios: melec = 0.07 mCDH = 0.01 mtherm = 0.04 mcomm = 0.03 mACS = 0.06 mstruct = 0.20

Mi known

750

200

40

990

mj = unknown M dry
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+

0.20 0.06

0.07 0.03

0.01 0.04

0.41

990 ( 1 0.41 )

1678 kg
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Mass Estimation, Power Subsystem


Givens: ALT Poa AF circular orbit altitude, km required orbital average power, watts area factor, if articulated arrays AF = 1, if omnidirectional in one plane, AF = 3.14, spherical coverage AF = 4 standard cell efficiency, 0.145 silicon, 0.18 gallium, 0.25 multi-junction

cell

If the required orbital average power is not settled, then estimate with: Poa ~ PREQpayload + 0.5 (MDry Mpayload) watts, mass in kg
Power for payload instruments and associated electronics ~ 1 watt/kg * Mpayload
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Dry bus mass, kg, ~ 0.5 watts/kg


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Mass Estimation, Power Subsystem


EtoD EtoD = 3.2. ( ALT = 0.576 50)
0.2

0.3
7 2 1.768. 10 . ALT

4 6.069. 10 . ALT

Maximum eclipse-todaylight time ratio, estimate good for 300<ALT<1000 km

Sun syncronous

1 EtoD 0.9 0.54 Area Psa = P OA . 997. cell Area SA = AreaFactor. Area Psa

Required solar array projected area normal to sun, m2 Physical panel area, m2

Total solar array panel area considering energy balance going thru eclipse and geometric area factors, m2

Feb 16 2005

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Mass Estimation, Power Subsystem


Mass of cells, insulation, wires, terminal boards: Melec ~ 3.8 x ASA Melec ~ 3.4 x ASA for multi-junction cells for silicon cells kg kg
93% packing efficiency

Mass of honeycomb substrates: Msubstrates ~ 2.5 x ASA Msubstrates ~ 2.0 x ASA for aluminum panels for composite panels kg kg

Since multi junction cells usually go on composite substrates, and silicon cells went on aluminum substrates, it all comes out in the wash:

MPANELS ~ 5.85 x ASA Mass of solar array panels, electrical and structure: MPANELS = Melec + Msubstrates kg

kg

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Mass Estimation, Power Subsystem


Mbattery = 0.06 Poa MPSE = 0.04 Poa MSAD = 0.33 Mpanels MSAdeploy = 0.27 Mpanels
Tracking array
(this can vary greatly due to the peak power input and charging profile allowed. High noon power input can be enormous sometimes, depending on orbit inclination and drag reduction techniques)

Battery mass, kg

Ni-Cads

Power systems electronics, kg

Solar array drives and electronics, kg

Solar array retention and deployment mechanisms, kg

Mpower = Mpanels + MSAD + MSAdeploy + Mbattery + MPSE Total power subsystem mass estimate, kg
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Power System Mass Example, givens


ALT = 700 km circular orbit altitude, sun synchronous AF = 1 area factor cell = 0.25 standard cell efficiency Mdry = 1000 kg Mpayload = 350 kg (35% of dry mass) Ppayload = 350 watts (1 watt/kg * 350kg) estimate Pbus = 325 watts (0.5 watts/kg * (1000-350)) estimate Poa = Ppayload + Pbus = 350 + 325 = 675 watts estimated orbital average power

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Power System Mass Example, calculations


EtoD = 0.576
4 6.069 .10 .ALT 7 2 1.768 .10 .ALT = 0.238

Sun synchronous

Area SA =

1 EtoD 0.9 0.54 = 4.203 AF .P oa . 997 . cell 5.85 .Area SA = 24.6 0.06 .P oa = 40.5 0.04 .P oa = 27 0.33 .M panels = 8.1

Total panel area m2

M panels M battery M PSE M SAD

= =

M SAdeploy = 0.27 .M panels = 6.6 M power


Feb 16 2005

= M panels

M SAD

M SAdeploy

M battery

M PSE = 106.8

kg
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Mass Estimation, Propulsion Subsystem


Givens: Isp V Mdry fuel specific thrust, seconds (227 for hydrazine, 307 bi-prop) deltaV required for maneuvers during the mission, m/s total spacecraft observatory mass, dry of fuel, kg

Isp is the amount of kick that the fuel has to offer per kg dMfuel/dt = Thrust / (g*Isp) kg per second

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Mass Estimation, Propulsion Subsystem


If the fuel is to be saved for a de-orbit maneuver:
V Isp.g

M fuel =

M dry . e

Or expressed as a ratio:

M fuel M dry

= e

V Isp.g

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Mass Estimation, Propulsion Subsystem


Approximate V to de-orbit to a 50km perigee: From 400km circular ~ 100 m/s From 500km circular ~ 130 m/s From 600km circular ~ 160 m/s From 700km circular ~ 185 m/s If the thrusters are too small for one large V de-orbit maneuver, then 2-3 times the calculated fuel maybe required (TRMM experience)
Add 10% for ullage

M fuel

M fuelDRAG

M fuelMANV

Total fuel mass, kg

M PropDry

0.25. M fuel

Propulsion system mass, dry, kg tank, thrusters, lines, etc... Total spacecraft observatory mass with fuel, kg

M wet

M dry

M fuel

Remember, the dry mass estimate now includes the mass of the dry prop system components. This means iterating with a better dry mass estimate for a better fuel calculation.
Feb 16 2005 ENAE 691 R.Farley NASA/GSFC

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Fuel Estimate Example


Orbit is a 700km circular, so V to de-orbit ~185 m/s Fuel is hydrazine, so Isp = 227 seconds g = 9.807 m/s2 Mdry = 1000 kg

Mfuel =

M dry . e

V Isp.g

1000 . e

185 227 .9.807

1 = 86.7 kg

M PropDry = 0.25 . M fuel = 21.7

kg

Fuel tank, thrusters, fuel lines, valves, etc

MS/C wet = Mfuel + Mdry = 1087 kg


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Vibration Primmer
A vibrating structure can be thought of as the superposition of many mode shapes Each mode has a particular natural resonant frequency and distortion shape If the resonant frequencies are sufficiently separated, then the structural response can be estimated by treating each mode as a single-degree-of-freedom (sdof) system
3 usual flavors of vibration: Harmonic
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Random
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Impulsive
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Harmonic (sinusoidal) Vibration, sdof


Transfer function

Hz Natural frequency of vibration for a single degree of freedom system

Recall: 2 f = Circular frequency, radians / s


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0.05 typical
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Harmonic Vibration, sdof

cont
Gain function

Harmonic output acceleration = Harmonic input acceleration x T f is the applied input sinusoidal frequency, Hz fn is the natural resonant frequency Typical structural values for Q: 10 to 20 For small amplitude (jitter), or cryo temperatures: Q >100 Resonant Load Acceleration = input acceleration x Q
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Natural Frequency Estimation evenly distributed mass and stiffness


E is the Youngs Modulus of Elasticity of the structural material

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Natural Frequency Estimation discrete and distributed mass and stiffness


E is the Youngs Modulus of Elasticity of the structural material

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Base-Driven Random Vibration


Random loads affect mostly smaller, high frequency components, not the overall spacecraft structure
So

Input spectrum So described in power spectral density g2 per Hz Miles equation gives a statistical equivalent peak g load for a single degree of freedom system, 68% of the time (1). For 99.73% confidence (3), multiply by 3.
Mechanically conducted random and Acoustically conducted random
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fn is the natural frequency of the system, Q is the resonant amplification, and So is the input acceleration power spectral density, g2/Hz

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Developing Limit Loads for Structural Design

Quasi-Static loads
Linear and rotational accelerations + dynamic Dynamic Loads included in Quasi-Static: Harmonic vibration (sinusoidal) Random vibration (mostly of acoustic origin) Vibro-acoustic for light panels Dont forget, there are

Thermal loads
Limit loads do not have stress factors of safety incorporated yet
Feb 16 2005 ENAE 691 R.Farley NASA/GSFC

payload mass vs. c.g. height limitations for the launch vehicles payload adapter fitting

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Launch Loads and Fundamental Frequency


Launch Vehicle Delta IV steady state dynamic Atlas II steady state dynamic H-II steady state dynamic Ariane V steady state dynamic Delta II steady state dynamic Axial Load Factor Naxial, gs 6.5 +/- 1.0 5.5 +/- 2.0 5.2 +/- 5.0 4.6 +/- less than 1.0 6.7 for 2000kg +/- 1.0 Lateral Load Factor Nlateral, gs +/- 2.0 +/- 0.7 +/- 0.4 +/- 1.2 2.8 +/- 2.0 +/- 0.25 +/- 0.8 +/- 3.0 +/- 0.7 27Hz min 10Hz min

15Hz min

10Hz min

30Hz min

10Hz min

18Hz min
Beware 32Hz MECO-POGO

10Hz min

35Hz min

15Hz min

Note: the static and dynamic loads do not occur at the same time (usually)
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Pegasus Loads
For Pegasus, quasi-static loads are equivalent to low frequency dynamic loads

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Pegasus Loads cont

To simplify, boil down to 3 load case combinations to analyze: Drop transient z ~ 6.5g lateral Stage burnout 10.5g axial, 1.7g lateral First lateral bending frequency > 20 Hz Aerodynamic pull-up 4.7g axial 3.5g lateral
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Loads for primary structure, example


If the structure meets minimum frequency requirements from the launch vehicle, then the low frequency sinusoidal environment is enveloped in the limit loads. Secondary structures with low natural frequencies may couple in, however, and should be analyzed separately.

Lcg

Reaction loads

The structural analyst will determine which load case produces the greatest combined axial-bending stress in the structure (I, A, mass and c.g. height)
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Loads example, cont


2 major load case combinations: a) 0.5g lateral + 6.5g axial b) 2.0g lateral + 3.5g axial Given: Mwet = 2000 kg g = 9.807m/s2 Lcg = 1.5m

Case a) load combination: Axial load = Mwet*Naxial*g = 2000*6.5*9.807 = 127491 N

Lateral load = Mwet*Nlateral*g = 2000*0.5*9.807 = 9807 N Moment = Lateral load * Lcg = 9807*1.5 = 14710.5 N-m Case b) load combination: Axial load = Mwet*Naxial*g = 2000*3.5*9.807 = 68649 N

Lateral load = Mwet*Nlateral*g = 2000*2.0*9.807 = 39228 N Moment = Lateral load * Lcg = 39228*1.5 = 58842 N-m

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Component Loads, Mass-Acceleration Curve


JPL acceleration curve for component sizing
100

Mass Acceleration Curve

Applicable Launch Vehicles: STS


Acceleration g's

Titan
gload i 10

Atlas Delta Ariane H2

1 1 10 i Mass kg mass 100 3 1 10

Proton Scout

This curve envelopes limit loads for small components under 500 kg Apply acceleration load separately in critical direction Add static 2.5 g in launch vehicle thrust direction

Feb 16 2005

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Simplified design curve for components on appendage-like structures under 80 Hz fundamental 63 frequency

Sizing the Primary Structure


rigidity, strength and stability

Factors of safety NASA / INDUSTRY, metallic structures


Factors of safety FS yield FS ultimate Verification by Test 1.25 / 1.10 1.4 / 1.25 (1.5 Pegasus) Verification by Analysis 2.0 / 1.6 2.6 / 2.0 (2.25 Pegasus)

Factors of safety for buckling (stability) elements ~ FS buckling = 1.4 (stability very dependent on boundary conditions.so watch out!)

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Primary Structure Simplified Model


E is the Youngs Modulus of Elasticity of the structural material

For example, in many cases, the primary structure is some form of cylinder

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Sizing for Rigidity (frequency)


Working the equations backwards. When given frequency requirements from the launch vehicle users guide for 1st major axial frequency and 1st major lateral frequency, faxial, flateral: Material modulus E times AXIAL STIFFNESS cross sectional area A Material modulus E times bending inertia I For a thin-walled cylinder:
I = R3 t ,
BENDING STIFFNESS

Select material for E, usually aluminum e.g.: 7075-T6 E = 71 x 109 N/m2

or t = I / ( R3) or t = A / (2 R)

A = 2 R t

Determine the driving requirement resulting in the thickest wall t. Recalculate A and I with the chosen t.
Tapering thickness will drop frequency 5% to 12%, but greatly reduce structural mass 66

Calculate for a 10% 15% frequency margin


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Sizing for Strength


Design Loads using limit loads and factors of safety Plateraldes = (M + Mtip) g NlimitL Paxialdes = (M + Mtip) g NlimitA Momentdes = Plateraldes * Lcg Lateral Design Load, N Axial Design Load, N Moment Design Load, N-m

Recalling from mechanics of materials:


(in a cylinder, the max shear and max compressive stress occur in different areas and so for preliminary design shear is not considered)

axial stress = P/A, bending stress = Moment*R/I

Max stress max = Paxialdes / A + (Plateraldes Lcg R) / I Margin of safety MS = {allowable / (FS x max)} 1 0 < MS acceptable For 7075-T6 aluminum, the yield allowable , allowable = 503 x 106 N/m2
With less stress the higher up, the more tapered the structure can be, saving mass
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Sizing for Structural Stability


Determine the critical buckling stress for the cylinder In the general case of a cone:

Compare critical stress to the maximum stress as calculated in the previous slide. Update the max stress if a new thickness is required.

Allowable Critical Buckling Stress 0 < MS acceptable


Sheet and stringer construction will save ~ 25% mass 68

Margin of safety MS = {CR /(FSbuckling x max)} 1


Check top and bottom of cone: max, I, moment arm will be different
Feb 16 2005 ENAE 691 R.Farley NASA/GSFC

Structural Subsystem Mass


For all 3 cases of stiffness, strength, and stability, optimization calls for tapering of the structure. The frequency may drop between 5% to 12% with tapering But the primary structural mass savings may be 25% to 35% - a good trade

Secondary structure (brackets, truss points, interfaces.) may equal or exceed the primary structure. An efficient structure, assume secondary structure = 1.0 x primary structure. A typical structure, assume 1.5. So, if the mass calculated for the un-optimized constant-wall thickness cylinder (primary structure) is MCYL, then the typical structure (primary + secondary): MSTRUCTURE ~ (2.0 to 3.5) x MCYL
This number can vary significantly

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Backup Charts, Extras

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Anatomy of s/c
Heat of boxes radiating outward

Transverse viewing, Earth observing type


Cylinder-in-box

Egg-crate extension

Instruments

FOV Drag make-up Propulsion module


Feb 16 2005 ENAE 691 R.Farley NASA/GSFC

Launch Vehicle I/F


Hydrazine tank equatorial mount on a skirt with a parallel load path ! The primary structure barely 71 knows its there.

Spacecraft Drawing in Launch Vehicle


Launch Vehicle electrical interface

Fairing access port for the batteries


Feb 16 2005

Pre-launch electrical access red-tag item


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XTE in Delta II 10 fairing


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Drawing of deployment phase

Pantograph deployment mechanism

EOS aqua
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Composite Materials
Pros Lightweight (Strength to Weight ratio) Ability to tailor CTE High Strength Good conductivity in plane Thermal property variation possible (K1100) Low distortion due to zero CTE possible Ability to coat with substances (SiO) Electrical bonding a problem Some types of joints are more difficult to produce/design Fiber print through (whiskers) Upper temperature limit (Gel temperature) Moisture absorption / desorption / distortion Tooling more exotic, expensive/specialized tooling (higher rpms, diamond tipped) Cons Costly

provided by Jeff Stewart


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Composite Material Properties


Graphite Fiber Reinforced Plastic (GFRP) density ~ 1800 kg/m3 If aluminum foil layers are added to create a quasi-isotropic zero coefficient of thermal expansion (CTE < 0.1 x10-6 per Co) then density ~ 2225 kg/m3 Aluminum foil layers are used to reduce mechanical shrinkage due to desorption / outgassing of water from the fibers and matrix (adhesive,ie. epoxy) NOTE! A single pin hole in the aluminum foil will allow water de-sorption and shrinkage. This strategy is not one to trust Cynate esters are less hydroscopic than epoxies
Shrinkage of a graphite-epoxy optical metering structure due to de-sorption may be described as an asymptotic exponential (HST data): Shrinkage ~ 27 (1 e - 0.00113D) microns per meter of length, where D is the number of days in orbit.
Microns per Meter Shrinkage( D ) 20

Shrinkage ( D)
40

27 . 1

. 0.00113D

Graphite-Epoxy Shrinkage in Vacuum

0 0 1000 2000 D Days 3000 4000 5000

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Mass Estimation, Propulsion Subsystem


Givens: Isp V TM YSM AP ALT Mdry fuel specific thrust, seconds (227 for hydrazine, 307 bi-prop) deltaV required for maneuvers during the mission, m/s mission time in orbit, years years since last solar maximum, 0 to 11 years projected area in the velocity direction, orbital average, m2 circular orbit flight altitude, km total spacecraft observatory mass, dry of fuel, kg
1 Area SAoa Area SA . cos EtoD 1

Solar array orbital average projected drag area for a tracking solar array that feathers during eclipse
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Mass Estimation, Propulsion Subsystem


Densitymax = 4.18 x 10-9 x e(-0.0136 ALT) DF = 1 0.9 sin [ x YSM / 11] Densityatm = DF x Densitymax
3.986 . 10 ( 6371
11

Approximate maximum atmospheric density at the altitude ALT (km), kg / m3 good for 300 < ALT < 700 km Density factor, influenced by the 11 year solar maximum cycle (sin() argument in radians)

Corrected atmospheric density, kg / m3

V circular CD Drag 2.2 1. 2

ALT)

Circular orbit velocity, m/s

Assumed Drag coefficient


2 Density atm. V circular . C D . A P

Drag force, Newtons

M fuelDRAG
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Drag. T M . 31.536 . 10 Isp . g

Fuel mass for drag make-up, kg


ENAE 691 R.Farley NASA/GSFC

If the mission requires altitude control, this is the approximate fuel mass for drag over the mission life
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Note: g = 9.807 m/s2

Mass Estimation, Propulsion Subsystem


Fuel mass for maneuvering
If maneuvers are conducted at the beginning of the mission (attaining proper orbit):
M fuelMANV M dry M fuelDRAG . e
V ( Isp .g)

Maneuvering fuel mass, kg beginning of mission case

If the fuel is to be saved for a de-orbit maneuver:

M fuelMANV

M dry . e

V ( Isp .g)

Maneuvering fuel mass, kg end of mission case (de-orbit)

Or expressed as a ratio:
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M fuelMANV M dry
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Deployable Boom, equations for impact torque

Io

Rotational mass inertia about point o, kg-m2

Dynamic system is critically damped Hinge point o Maximum Impact torque at lock-in, N-m d/dt can just be the velocity at time of impact if not critically damped
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Static Beam Deflections


For Quick Hand Calculations, these are the most common and useful

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Rigid-body accelerations
Linear force F = m x a = m x g x Nfactor
N is the load factor in gs Low frequency sinusoidal below first natural frequency will produce near-static acceleration a = A x (2 f)2 where f is the driving frequency and A x = A sin(t) is the amplitude of sinusoidal motion

Rotational torque Centrifugal force

Q = I x alpha Fc = m x r x 2

v = A cos(t) a = -A2 sin(t)

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Combining the loads to form quasi-static levels


Limit Load = Static + dynamic + resonant + random
(low frequency)

Note: The maximum values for each usually occur at different times in the launch environment, luckily. The primary structure will have a different limit load than attached components. Solar arrays and other low area-density exposed components will react to vibro-acoustic loads.
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Loads for a component, example


Mpayload = 500 kg Mkickmotor = 50 kg Tstatic = 30000 N Tdynamic = +/- 10% Tstatic at 150 Hz
(resonant burn, chuffing)

dry mass

m = 1 kg

Antenna boom component

fnaxial = 145 Hz with Q = 15 fnlateral = 50 Hz with Q = 15 L = 0.5m R = 1m

The axial frequency is sufficiently close to the driven dynamic frequency that we can consider the axial mode to be in resonance.

= 10.5 rad/s (100 rpm)


Random input So = 0.015 g2 per Hz

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Spinning upper stage example, cont


Axial-to-lateral coupling

Length L Radius R

L Paxial Deflection y: y = R ( / )2 [ 1 ( / )2 ] Axial-to-lateral coupling AtoL = y / L

R y

Deflection y Lateral circular bending frequency, rad/s


= 2 fnLateral

Plateral

Equivalent additional lateral load = AtoL x Paxial


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Loads for a component, cont


Static axial acceleration GstaticA = Tstatic / g (Mpayload + Mkickmotor) gs Dynamic axial acceleration GdynA = Tdynamic x Q / g (Mpayload + Mkickmotor) gs gs Random axial acceleration GrmdA = 3 sqr[0.5 fnaxial Q So] Axial Limit Load Factor, gs, Naxial = GstaticA + GdynA + GrmdA Axial Limit Load, Newtons, Paxial = g x m x NaxialL Static lateral acceleration GstaticL = (R+y) 2 / g Random lateral acceleration GrmdL = AtoL x 3 sqr[0.5 fnlateral Q So] Dynamic lateral acceleration GdynL ~ 0 Lateral Limit Load Factor, gs, Nlateral = GstaticL + GdynL + GrmdL Lateral Limit Load, Newtons Plateral = g x m x Nlateral Moment at boom base Moment = L x Plateral + y x Paxial gs

gs gs

gs

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