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Spacecraft Structures

Spacecraft Structures. Heather Reed Mechanical Engineering Manager Laboratory for Atmospheric and Space Structures reed@lasp.colorado.edu. What is a structure?. Why does a spacecraft need a structure? PRIMARY or Secondary?. Lifecycle of a Structure. REQUIREMENTS (NEEDS). DESIGN.

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Spacecraft Structures

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  1. Spacecraft Structures Heather Reed Mechanical Engineering Manager Laboratory for Atmospheric and Space Structures reed@lasp.colorado.edu

  2. What is a structure? Why does a spacecraft need a structure? PRIMARY or Secondary?

  3. Lifecycle of a Structure REQUIREMENTS (NEEDS) DESIGN ANALYSIS BUILD TEST INTEGRATION STUDENT NITRIC OXIDE EXPLORER (SNOE)

  4. REQUIREMENTS • What does this spacecraft structure need to do? • Accessibility • Lift points • Vibe • Acoustic • Shock • Thermal • Radiation ON-ORBIT CONDITIONS ROCKET LAUNCH GROUND TESTING

  5. DESIGN – What shape will it be? • SNOE was a “spinner”

  6. DESIGN – What will it be made out of? • Materials selection • Stiffness vs. Strength • Car suspension – STRONG CAR, weak connection to the road • WEIGHT  CHEAPEST RIDE TO SPACE = $35,000 per lb • Cleanliness • Specific plastics only • Materials that can be scrubbed • Aluminum is a great material

  7. DESIGN – How will it be built? • Manufacturability • Strongest structure is all one piece • How easy is it to assemble? • Primary structure $$ < 1% of SNOE mission budget ($8M)

  8. DESIGN – Will it fit? • Solid Modeling • Static or Dynamic SPACECRAFT ROCKET NOSECONE ROCKET SECONDARY STAGE

  9. Solid Modeling - SolidWorks

  10. ANALYSIS - Modal Simulation Results • 821 Hz: First predicted high mass participation mode. • 741 Hz: Lowest frequency mode is a local connector bracket mode. • Z-axis has very little mass participation below 2000 Hz. • Two principal mode shapes shown below: Mode 2 – 821 Hz – Mode shape plot Rocking in the Y-direction Mode 6 – 1270 Hz – Mode shape plot Rocking in the X-direction

  11. BUILDING IT – Your best laid plans • Fabrication – Do 2 planes meet perfectly? • Assembly – How clean is clean?

  12. Why TEST? • Vibration Testing • Thermal Vacuum Testing • Acoustic Testing • Shock Testing • Strength Testing • Spin Balance • Mass properties NASA Goddard Gold Rules: • TEST AS YOU FLY, FLY AS YOU TEST

  13. TESTING – Vibration Testing • Mass model testing – Good practice • Test sensors - Accelerometers SNOE SPACECRAFT LARGE SPEAKER “VIBE TABLE” AT BALL AEROSPACE

  14. Vibration Test Specification

  15. TESTING – Thermal Vacuum • Less cooling without air – Electronics • Thermal expansion – Causing binding • More friction without air – Moving parts • HOT/COLD Operational and Survival limits SNOE SPACECRAFT LARGE TANK “RAMBO” AT BALL AEROSPACE

  16. INTEGRATION to the Pegasus

  17. Secondary Structure – Solar Arrays

  18. Heather Reed, CU Mechanical Eng 97’ • Work during Undergrad studies, BS ME in 1995 • Space Grant College • NIST, NDE lab • CU football & basketball security • Hart Ranch snack shop • Work during Grad studies on SNOE, MS ME in 1997 • FEA, Solar panel substrate, Nutation damper, Torque rods, Thermal blankets • Employed at LASP after graduation • ME Manager in 2001, 8 ME’s then, 23 ME’s now • Current program is MAVEN, mission to MARS • Starting Program Management this week

  19. EUV on MAVEN going to Mars LPW-EUV Langmuir Probe and Waves (LPW) – LASP / SSL LPW/Extreme Ultra-Violet (LPW-EUV) – LASP

  20. Testing • Engineering Unit testing • Mechanism Life Testing – Vibe, Life Test cycling • Luxel filter qualification – Vibe, thermal cycles • Light leak testing • Torque margins • Spring force • Magnetic field • Flight Unit testing • Vibe test • Random Vibe, response limit • Strength verification = ? • Mechanism Run-in • Torque margins • Spring force • Light leak testing

  21. 22V 30V 36V 30V 4280 Cycles 22V 30V 36V 30V -5°C -35°C 35°C 50°C 200 Cycles 22V 30V 36V Aperture Mechanism Life Test Plan

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