Payload Assembly Plan

Flight Hardware and Components

Table I, Table II, and Table III summarize the purchased hardware, components, and flight samples respectively.

Table I: Payload Flight Hardware List

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Table II: Payload Flight Components List

Payload Flight Component List

Table III: Flight Samples and Support Cups List

Payload FM parts inspections

Table IV: Payload BOM

IRIS BOM

Upper Module Assembly Instructions

The following instructions are to guide assembling the payload upper module. Also, the assembly procedure is shown in Video 1.

1) Sample Plate Assembly Instructions: DONE ✔

  1. Install Helicoils into Payload Sample Plate(57.8g) as shown in Figure 1.

  2. For each sample and sample support, using the sample layout shown in Figure 3:

    1. Place a UMS-0007 disc spring in the centre of the designated sample well within the payload sample plate

    2. Taking care not to disturb the disc spring, place the sample support in the well

    3. Place the sample in the well on top of the sample support

  3. Carefully place the UMS-0004 sample plate lid on top of the sample plate

  4. Carefully place the sample plate lid mask on top of the sample plate lid. Use Kapton tape to fix the mask and lid.

  5. Apply UMS-0085 Loctite 242 and loosely install the fasteners shown in Figure 2 onto the sample plate. All 2-56 fasteners (UMS-0011) are to be tightened to 0.28 Nm and all 4-40 pan fasteners (UMS-0009 and UMS-0010) to 0.59 Nm.

  6. Alternately tighten the fasteners into the sample plate by 90 degree turns using a calibrated torque wrench until each fastener reaches the desired installation torque. DO NOT TIGHTEN ANY FASTENERS COMPLETELY WITHOUT ALTERNATING BETWEEN THEM AS THIS MAY CAUSE SAMPLES TO CRACK!

  7. Assemble the UMS-0186 Gnomon pin and UMS-0265 gnomon base(2.3g).

  8. Install the UMS-0002 Gnomon assembly into the UMS-0019 Sample Plate Assembly using four UMS-0266 fasteners. Apply UMS-0085 Loctite 242 and install fasteners loosely before tightening each fastener in 90 degree increments, cycling between fasteners, using a calibrated torque wrench to 0.47 Nm. (92.2g whole assembly)

2) Thermistor Assembly Instructions: DONE ✔

Epoxy Procedure:

  1. Some components can separate during shipping and storage, it is recommended to mix the components prior to use. Use a clean spatula to mix the STYCAST 2850 and gently swirl the catalyst bottle.

  2. Use a clean spatula to remove 100 g of the STYCAST 2850 to a clean container.

  1. Measure out 3.5 g of catalyst 9.

(Note: the catalyst is in a glass bottle, please return it to its container\wrap ASAP to minimize the amount of time the catalyst bottle is exposed to the light.)

  1. Blend components by hand, using a kneading motion for 2 to 3 minutes.

Note: As long as you keep it slow during the mixing and do not whip up the mixture, there should be no need for deairing at all.

  1. Inspect the mixture for air bubbles. If air bubbles are present you could a)restart the epoxy procedure, taking extra care in step 4. b)degas the

Installation Procedure:

    1. Solder wires to the thermistor.

    2. Gently wrap the thermistor leads with Kapton tape for insulation.

    3. Mix the epoxy as outlined by the Epoxy Procedure.

    4. Clean the application area with IPA and lint free wipes to remove dust, moisture or any other contamination.

    5. Place the payload sample plate face down, elevating it off the group by propping it on supports.

    6. Dip the whole thermistor into the mixed epoxy covering the bead.

    7. Place the dipped thermistor in the cleaned application area.

    8. Apply Kapton tape (2-3 pieces) across the leads, to provide pressure to hold the thermistor in contact with the surface.

    9. Leave the thermistor to cure for 16 to 24 hours @25 C.

3) Solar Deployment Assembly Instructions:

  1. Install a UMS-0013 helicoils into the top and bottom of the UMS-0097 payload rear support legs (for four helicoils total between the two parts). DONE ✔

  2. Install UMS-0016 helicoils to both sides of UMS-0188 solar panel burn wire base ( eight helicoils in total for two parts). DONE ✔

  3. Install UMS-0189 solar panel burn wire cylinder between two base using UMS-0175 fasteners (0.050") and UMS-0177 nuts (¼ " wrench).

  4. Install UMS-0097 rear supports to the UMS-0188 base using eight UMS-0174 fasteners (0.050").

  5. Install burn resistor supports using two UMS-0211 bolts, eight UMS-0212 spacers (4 per bolt, 2 per each side), and two UMS-0177 nuts. See Figure 4B for Visualization.

  6. Apply Loctite 2151 epoxy to burn wire cylinder and burn wire spacers and insert UMS-0185 burn resistor.

  7. Let Loctite 2151 epoxy cure for 24 hours.

Sample Plate Helicoil Positions

Figure 1: Sample Plate Helicoil Positions

Sample Plate Fastener Positions

Figure 2: Sample Plate Fastener Positions

Payload Sample Positions

Figure 3: Sample Positions

4) Upper Shell Assembly Instructions: DONE ✔

  1. Connect the UMS-0019 sample plate assembly to the solar deployment assembly using the two UMS-0015 fasteners (3/32" Hex) and two UMS- 0014 washers as shown in Figure 4. Apply UMS-0085 Loctite 242 and torque the fasteners to 1.0 Nm using a calibrated torque wrench.

  2. Install the whole assembly into the UMS-0027 Upper Payload Shell using four UMS-0117 fasteners (1/16" Hex) to 1.0 Nm using a calibrated torque screwdriver as seen in Figure 5. Apply UMS-0085 Loctite 242 to the fasteners before assembling them.

Figure 4A: Sample Plate Support Mounting

Figure 4B: Deployment System Visualization

Figure 5: Sample Plate Installation into Structure

Sample plate assembly and loctite.mov

Video 1: Sample plate assembly procedure (Credit: Ali Barari)

Lower Module Assembly Instructions

1) Payload Cameras Assembly Instructions: DONE ✔

  1. De-solder the 22-pin header on the two supplied cameras and replace them with UMS-0263 22-pin headers so that the header is on the same side of the camera board as the camera lens (as seen in Figure 8). Ensure that no more than 1.5 mm of header is exposed on the rear of the camera board. DONE ✔

  2. Mechanically mount the UMS-0261 camera support to UMS-0005 the payload control board by doing the following: (Video 2)

a. Place the UMS-0261 Camera Support on the control board as indicated in Figure 11. The pockets of the camera support should sit on the side of control board that has MCU and flash components.


b. Mount the UMS-0020 cameras to the UMS-0261 Camera Support and

UMS-0005 Payload Control Board so that the camera passes through the hole and the camera pins pass through the control board as shown in Figure NOTE: Video 2 shows a different lens. The supplied cameras have the black lens and can pass through the board unimpeded.

c. For each of the camera’s four mounting locations, install a UMS-0113 1-64 pan ½” fastener (#0 Drive).

d. Flip the assembly slowly.

e. For each fastener, install one UMS-0115 No.3 washer and one UMS-0193 spacer.

  1. Solder the camera to the camera control board.

  2. Remove the default lenses and replace them with flight lenses UMS-0116.

  3. Adjust the lenses with approximately 6 revs. Then, fix the lenses in position by fastening the screws (Head Phillips Screws 1-64 Thread Size, 3/16" Long) on the body of the lens.

  4. Install the UMS-0262 camera baffle as shown in Figure 9.

  5. For each fastener, install the one UMS-0114 1-64 nuts. (Apply Loctite 242 to the inside thread of each nut before installing them)

Figure 6: Payload Lower Shell Helicoil Locations, Denoted by 1s

Figure 8: Final camera board assembly

Figure 9: Camera Mounting System

Figure 11: Control board assembly

Figure 10: Assembled Payload Control Board (Note: Baffles are slightly different)

My Movie.mov

Video 2: Payload camera assembly instruction (Credit: Ali Barari)

2) Sun Sensor Assembly Instructions: DONE ✔

  1. Mount four UMS-0423 screws (Slotted Drive Style) to the UMS-0381 Sun sensor assembly using four UMS-0422 nuts (External Hex Drive Style), ensuring to apply Loctite to the male threading of the screws.

  2. Place three UMS-0377 spacers along the remaining thread of each UMS-0423 screw (Slotted Drive Style), as shown in Figure 13.

  3. Apply Loctite to male threading of the UMS-0423 screws (Slotted Drive Style).

  4. Mount sun sensors to the UMS-0026 payload lower shell using four UMS-0422 nuts (External Hex Drive Style) from the inside of the shell and the UMS-0423 screws (Slotted Drive Style) from the outside, as shown in Figure 14.

  5. Pull the hanging sun-sensor wires from the ADCS module through the reserved holes (shown in the Figure 12) on the PLD lower shell

  6. Connect the 10-pins connector to the header of the sun sensor.


Figure 12: Pass through hole for sun sensor wires

Figure 13: Sun sensor assembly as shown from outside

Figure 14: Mounting points for Sun sensors from inside the payload shell.

3) Harnessing and Control Board Assembly Instructions: DONE ✔

Harnessing:

  1. Get wires with correct lengths as indicated in Table I.

  2. Strip back about 1/2’’ (1.2 cm) of insulation to expose the bare wire.

  3. Solder wires A, B and C and E to their corresponding positions on PLD control board UMS-0252.

  4. Solder wires A, F and D to connector 2b, following the pin-wire correspondence table on Wiki-harness ICD.

  5. Solder wires B and G and I to connector 5b, following the pin-wire correspondence table on Wiki-harness ICD.

  6. Solder wires F to connector 3a, following the pin-wire correspondence table on Wiki-harness ICD.

  7. Solder wires C and G to connector 6a, following the pin-wire correspondence table on Wiki-harness ICD.

  8. Solder wires D to solar deployment's resistor UMS-0189.

  9. Solder wires E from sample plate thermistor UMS-0045 to the control board.

  10. Let wire I go through the deployment operation window on the upper shell, such that the open end of wire I is now outside the shell.

  11. Mount connectors 2b and 5b to the payload lower shell UMS-0026, follows steps below:

    1. Firstly, insert the bolts UMS-0208 to the payload lower shell, make sure the bolt head is at the -z surface of the lower shell.

    2. On the +z surface, put 1 washers UMS-0210 to each of the bolt (so 2 washers in total for every connector), then insert the connector (2b and 5b are identical UMS-0205) .

    3. Put nuts UMS-0209 to the rest of bolts and tighten it.

  12. If assembled correctly, the connector assembly should look like Figure 15.

  13. Install the four UMS-0013 4-40 0.224" helicoils into the UMS-0026 payload lower module shell's mounting holes from outside of the shell. When installing helicoils, keep screwing until the bottom of the helicoils reach to the other side of the hole. DONE ✔

  14. Apply UMS-0085 Loctite 242 to the UMS-0012 fasteners (3/32" Hex). Then, install fasteners onto the control board as located in Figure 16.

  15. Apply epoxy on UMS-0193 spacers and mount it on the bottom side of the control board. (fasteners should go into the spacers)

  16. Torque the fasteners to 1.0 Nm using a calibrated torque wrench.

  17. Mount connectors 3a and 6a to the payload upper shell UMS-0027, following the same assembly steps of connectors 2b and 5b, with the number of washers (UMS-0210) if changed from 1 to 4 for each bolt.

  18. Mount the connector lock mechanism to the upper shell UMS-0027, and follow the steps listed below, after this step, there should be 4 bolts on the upper shell.

  19. Insert the 7/16’’ screw UMS-0270 into the 4 holes (the holes are shown in Figure 17) note that the screw head is within the payload module.

  20. On the other side (outside of the payload upper shell), put nuts UMS-0268 on the screws and then tighten them.

  21. Put the connector lock legs UMS-0272 onto the shell through the screws UMS-0270. Note that the vertical wall should be on the close-to-connector side.

  22. Put nuts UMS-0268 on the screws such that the connector lock legs UMS-0272 are fixed on the shell.

  23. Stack payload upper shell UMS-0027 onto payload lower shell UMS-0026.

  24. Use zip-tie UMS-0219 to attach all wires to the lower shell, the zip tie holes are on the +X side wall of lower shell. Make sure the node of the zip-tie is inside of the shell.

  25. Adjust the wire length in-between the two shell zip-tie nodes (one on -Y side wall of lower shell, another on the +X side wall of lower shell), and use zip-tie to bundle those wires up at the middle. After this step, the wires in the lower half of the payload module should all be fixed to the wall.


Figure15: Inter-module connector assembly

Figure 16: Payload control board mounting fastener locations

Figure 17: Zip tie holes

Note: The power connector 2b should be in the hole at the -Y side, as shown in Figure 18. If look from outside the module, the connector will look like Figure 16. (note that in the picture there is only one connector is assembled as an example, in actual assembling, there should be 2 connectors.)

Figure 18:

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Table I:

Appendix:

The pictures below are showing the wire routing for the final PLD assembly.

Notes:

  • The number of wires in Table I is not reflected in the pictures below, the pictures are only for showing wire routing.

  • The thermistor wires should go to the backside of the sample plate.

  • Figure 19 is showing the assembly after step 17. These wires are most going between PLD lower & upper half, (except sun sensor wires).

  • Figure 20 is showing the assembly after step 24. The wires should be bundled and attached to the shell using zip-tie, this is to exhaust the extra wire length that is designed for the ease of assembling.

Figure 19:

Figure 20: