Iris Assembly Plan Template

Introduction

Module Assembly

POW Module - UMS-0047

ADCS Module - UMS-0055

PLD Module

COM/CDH Module - UMS-0049

Iris Integration

Introduction

This page provides detailed step-by-step instructions in the assembly of the subsystem modules, as well as the integration into the Iris spacecraft. Instructions are divided into two parts: Module Assembly (which can be completed concurrently and outlined in Figure 1) and Iris Integration (outlined in Figure 2).

NOTE: Inspection verification activities will confirm correct installation and will be ID's should be referenced throughout this page.

Module Assembly

Figure 1: Module assembly flowchart.

POW Module - UMS-0047

Required GSE:

Tools: Torque Wrench Set, Loctite, Needle Nose Pliers
Verification Activities: Provide a list of all verification activities that will be used to confirm the module was properly assembled.
PPE: Clean Room Smocks, Gloves, ESD Wristband, mask, hair cover, beard cover, safety glasses
Hardware

Assembly Plan Part list

Instructions:

Weigh Batteries, Shells, and Electronic Boards.
Connect umbilical to POW shell.
1. Place the umbilical connector into the corresponding reserved hole on the lower power shell.
2. apply Loctite to male threading of two UMS-0208 bolts.
3. Insert the UMS-0208 bolts into the module shell. See POW figure 1 for umbilical location.
4. Tighten UMS-0209 nuts onto the UMS-0208 bolts to a torque of 1.13 in-lbf.
Assemble saddle subassembly.
1. Assemble the heaters, thermistors and thermostat on the saddle following the battery saddle assembly procedure [Battery Saddle Installation Procedure - Google Docs ].
2. Mix the thermal epoxy following [link to epoxy mixing procedure].
3. Apply thermal epoxy on the 2 bottom battery holders.
4. Place 2 of the cells on the bottom slots of the saddle. Take extra care to align the cells with the center of the saddle holders.
5. Wait for the epoxy to cure (at least 24 hours).
6. Mix the thermal epoxy following [link to epoxy mixing procedure].
7. Apply thermal epoxy on the 4 top battery holders.
8. Place 4 of the cells on the top slots of the saddle. Take extra care to align the cells with the center of the saddle holders.
9. Wait for the epoxy to cure (at least 24 hours).
10. Connect the battery harnessing wires by soldering wires to the solder tabs according to [Link to battery harness].
Weigh Saddle Subassembly.
Connect saddle subassembly to lower POW shell.
1. Place Saddle subassembly inside the lower shell.
2. Place UMS-0212 washers on each of the four UMS-0254 screws.
3. Apply Loctite to UMS-0254 screws.
4. Tighten UMS-0254 screws to saddle from the external -Z face of the lower POW shell to 1.13 in-lbf. See POW figure 3 for bolt locations.
5. Ensure wire I and umbilical wire (P,Q,R) go through the opening area on battery saddle indicated in figure ** to arrive at upper power module.
Connect star ground from POW board to POW lower shell.
1. Route wire from POW board to designated starground hole.
2. ****
Harness 17-27.
Connect inter-modular connectors to the upper POW shell.
1. Place and temporarily fasten using Loctite: two UMS-0210 spacers over each hole of each UMS-0206 on the female side of the connector for a total of four spacers per connector.
2. Place the two UMS-0206 connectors into the upper POW Shell such that the female ends stick out of the shell towards the +Z face of the satellite.
3. Apply Loctite to the threading of the four UMS-0208 screws.
4. Place UMS-0208 screws from the outside of the shell into the connector holes.
5. Tighten UMS-0209 Nuts onto the UMS-0208 screws to a torque of 1.13 in-lbf.
6. Place four UMS-0270 into the upper POW shell male connector bracket holes such that the socket heads face the -Z direction.
7. Apply Loctite to the UMS-0270 screws.
8. Tighten UMS-0268 nuts onto each of the UMS-0270 screws to 1.13 in-lbf.
9. Place each UMS-0272 onto their UMS-0270 screws on the upper POW shell.
10. Apply Loctite to the UMS-0270 screws again.
11. Tighten UMS-0268 nuts onto each of the UMS-0270 screws to finish attaching the locking bracket to the shell at a torque of 1.13 in-lbf
Place the upper POW shell onto the lower POW shell.
Make sure the solar panel wires S.T & S.P &T.T &T.P &U.T &U.P are going to outside the power module through the reserved window on power upper shell.
Weigh finished submodule.

POW figure 1: Umbilical Connector location

POW figure 3: Saddle mount hole locations

ADCS Module - UMS-0055

Required GSE:

Tools: Torque Wrench Set, Needle Nose Pliers, Loctite, Wire Strippers
Verification Activities: Provide a list of all verification activities that will be used to confirm the module was properly assembled.
PPE: Clean Room Smocks, Gloves, ESD Wristband, mask, hair cover, beard cover, safety glasses
Hardware

Assembly Plan Part list

Instructions:

Weigh Torque Rods, Shell, and ADCS Board.
Assemble ADCS board subassembly.
1. TBD
Get wires with correct lengths as indicated in TABLE 2 (ADCS Wire Lengths).
Strip back about 1/2’’ (1.2cm) of insulation to expose the bare wire.
Solder wire C to connector 2a, follow the pin-wire correspondence table on Wiki-harness ICD.
Solder wire A and B to connector 5a, follow the pin-wire correspondence table on Wiki-harness ICD.
Solder the other end of wire A to +z surface of ADCS board.
Solder the other end of wire F and G to -z surface of ADCS board.
Solder Wire E to headers.
Connect one end of Wire E to the +Z surface of the ADCS board.
Route Wire E through the designated hole on the top face of the ADCS shell.
Connect inter-modular connectors to ADCS shell.
1. Place and temporarily fasten using Loctite: two UMS-0210 spacers over each hole of each UMS-0206 on the female side of the connector for a total of four spacers per connector. See ADCS Figure 1 for visualization.
2. Place the two UMS-0206 connectors into the Shell such that the female ends stick out of the shell towards the +Z face of the satellite.
3. Apply Loctite to the threading of the four UMS-0208 screws.
4. Place UMS-0208 screws from the outside of the shell into the connector holes. See ADCS Figure 2 for visualization.
5. Tighten UMS-0209 Nuts onto the UMS-0208 screws to a torque of 1.13 in-lbf.
Place wires B and C through the gap between the board and the shell as indicated in ADCS Figure 3.
Connect ADCS board to ADCS shell.
1. At each corner of the ADCS board: place each of the four UMS-0274 into each corner hole such that screw heads are oriented towards the -Z face of the satellite.
2. Place UMS-0275 spacers over each screw hole on the ADCS shell. Temporarily securing each spacer in place with a drop of Loctite. See ADCS Figure 4.
3. Place Loctite onto the threading of each of the UMS-0274 screws.
4. Position the ADCS board into the shell.
5. Tighten UMS-0274 screws into the holes of the shell to a torque of 1.13 in-lbf.
Solder the other end of wire C to connector 1b, follow the pin-wire correspondence table on Wiki-harness ICD.
Solder the other end of wire B to connector 4b, follow the pin-wire correspondence table on Wiki-harness ICD.
Solder wire F to connector 4b, follow the pin-wire correspondence table on Wiki-harness ICD.
Soler wire G to connector 1b, follow the pin-wire correspondence table on Wiki-harness ICD.
Solder the Z-magnetorquer to -Z surface of the ADCS board.
Connect vertical torque rod to ADCS shell.
1. Align Torque Rod with Mounting Hole on the +X face of the Shell.
2. Apply Loctite to the UMS-0117 Screw threading.
3. Tighten UMS-0117 screw to a torque of 1.35 in-lbf.
Temporarily tack wires 13-16 down securely onto the shell while waiting for Sunsensor assembly using Kapton tape.
Weigh finished submodule.

ADCS Figure 1: Intermodular Connector Assembly cross section

ADCS Figure 2: Intermodular Connector Bolt Locations

ADCS Figure 4: Board spacer locations

PLD Module

PLD Module assembly plan to be transfered over from the following page: https://sites.google.com/site/manitobasat1/subsystems/payload/payload-flight-assembly-plan

Instructions:

Step 1
Step 2
1. Step 2.1 (if needed)

COM/CDH Module - UMS-0049

Heinz Notes (delete when populating): Make sure to have as granular steps as possible. Include images where possible to make life easy for the person doing this activity, and provide links to other pages that you think would provide helpful supporting information. All critical information should be included here.

Required GSE:

Tools: Torque Wrench, Needle nose pliers, Loctite, Soldering Station
Hardware: UMS-0029, UMS-0357, UMS-0183, UMS-0358, UMS-0360, UMS-0550, UMS-0549, UMS-0359, UMS-0361, UMS-0362, UMS-0363, UMS-0364, UMS-0365, UMS-0366, UMS-0212, UMS-0367, UMS-0254, UMS-0202, UMS-0253, UMS-0177, UMS-0011, UMS-0259, UMS-0356, UMS-0428, UMS-0427, UMS-0426, UMS-0383, UMS-0382, UMS-0371, UMS-0001, UMS-0076, UMS-0267, UMS-0372, UMS-0369
PPE: Clean Room Smocks, Gloves, ESD Wristband, mask, hair cover, beard cover, safety glasses

Verification Activities: Provide a list of all verification activities that will be used to confirm the module was properly assembled.

Instructions:

Snap off excess screw threading for three UMS-0360 screws outside of clean room (0.5cm excess).
Label the three shortened screws as bucket assembly screws for later during clean room assembly.
Weigh the UMS-0441 ground plane, and UMS-0029 shell.
Assemble antenna bucket subassembly
1. Install UMS-0253 Helicoil at the hinge join location of the UMS-0361 bucket.
2. Apply Loctite to a UMS-0202 screw.
3. Attach UMS-0357 hinge to UMS-0361 bucket using the UMS-0202 screw. See COMS Figure 1.
4. Slide the UMS-0562 switch into UMS-0361 such that bolt holes align with the holes on the bucket and the hinge is located towards the +Y face of the satellite. See COMS figure 2 for details.
5. Apply loctite to the male threading of two UMS-0564 screws.
6. Secure the UMS-0562 switch into UMS-0361 by tightening the two UMS-0564 screws into the bucket to a torque of 1.10 in-lbf.
7. Place the UMS-0358 door and UMS-0183 spring into the UMS-0357 hinge and hold it in place by inserting a shortened UMS-0360 screw such that the screw head is oriented towards the -Z direction.
8. Stack the UMS-0363 bucket lid and then the UMS-0364 spring catch onto the UMS-0361 bucket and hold in place by inserting two shortened UMS-0360 screws such that the screw head is oriented towards the -Z direction.
9. Inspect that UMS-0364 spring catch is properly pushing against the UMS-0183 spring. See COMS figure 3 for proper placement.
Weigh the antenna bucket subassembly.
Hold Antenna bucket subassembly against the COMs Shell such that the screws are placed within their attachment holes. See COMS figure 4 for proper placement.
Apply Loctite to the three UMS-0360 screw threads.
Tighten UMS-0177 nuts to the screws to a torque of 1.13 in-lbf, locking together the bucket subassembly to the shell.
Assemble COMS board subassembly
1. Place four UMS-0427 screws into the transceiver mounting holes such that the screw heads face the -Z direction.
2. Stack a UMS-426 spacer on each of the four UMS-0427 screws on the +Z side of the COMS board.
3. Place the Transceiver onto its mounting screws.
4. Apply loctite to the male threading of the UMS-0427 screws.
5. Tighten a UMS-0428 nut onto each UMS-0427 screw to a torque of 1.35 in-lbf.
6. Place one UMS-0557 self-adhesive zip tie holder onto the COMS board +Z face such that the holder is 18.25mm from the bottom edge of the board and 30mm from the right edge as shown from the perspective of COMS figure 6.
7. Connect the MCX-SMA right angle adapter (UMS-0425) to the transceiver MCX port.
8. Grab two UMS-0254 screws and place a UMS-0212 washer on each.
9. Place the UMS-0254 screws with washers into the mounting holes for the burn wire holder and burn wire resistor such that the screw heads are pointing in the -Z direction. See COMS figure 6 for the positions.
10. Tighten UMS-0365 and UMS-0366, burn wire holder and burn resistor holder to their screws to a torque of 1.13 in-lbf.
11. Attach UMS-0362 Transceiver wire to the board with a zip tie routed through the zip tie holder.
12. Ensure UMS-0362 wire routing matches COMS figure 6.
13. Screw the transceiver wire to the Transceivers MCX-SMA adapter.
Weigh the COMs board and CDH boards.
Get all wires ready with the correct length as indicated in TABLE 1 (COMS/CDH wire lengths) .
Strip all wires back about 1/2’’ (1.2cm) of insulation to expose the bare wire to be ready for soldering.
Solder power supply wires (wire A) to antenna deployment tab.
The free end of wire A should go through the gap between COMS board and the shell.
Solder wire B, C and D to CDH board, following the pin-wire correspondence table on Wiki-harness ICD.
Mount CDH board to COMS board via the ribbon cable (4 wires).
Using four UMS-0360 screws; stack the CDH board and COM board with UMS-0383 spacers between the two.
Route wires as shown in figure 2 (the figure is only used to indicate the wire routings, disregard the number of wires displayed).
Solder wire A and B to connector 3b (UMS-0205), follow the pin-wire correspondence table on wiki harness ICD.
Solder wire C and D to connector 6b (UMS-0205), follow the pin-wire correspondence table on wiki harness ICD.
Use Loctite to temporarily stack and stick UMS-0382 spacers onto the COMs shell at locations indicated in COMs figure 5.
Apply Loctite to the UMS-0360 screws.
Place CDH/COM stack into the COM Shell.
Tighten the UMS-0360 screws to 1.13 in-lbf, locking in the CDH/COM board stack.
Route the Coax cable ground and lead cables towards the antenna door.
Solder the Antenna (UMS-0359) to the Coax cable lead wire.
Bolt antenna to the door using UMS-0549 screws and UMS-0550 nuts tightened to 1.00 in-lbf while using Loctite on the screw male threading.
Weigh the finished Submodule.

COMS figure 1: Bucket-Hinge Attachment point

COMS figure 2: Inhibit switch location

COMS figure 3: Spring proper placement

COMS figure 4: Antenna Bucket Assembly Mount Points

COMS figure 5: Spacer locations

COMS figure 6: COMs Board Assembly

Iris Integration

Figure 2: Iris integration flowchart

Required GSE:

Tools: Required tools such as cleaning equipment, chemical, jigs, hand tools, consumables, etc.
Hardware: Iris part IDs that are needed for completion.
PPE: Personal protection equipment for tests and environment (clean room smock, face masks, gloves, ESD equipment, etc).

Verification Activities: Provide a list of all verification activities that will be used to confirm the module was properly assembled.

Instructions:

ADCS & Power module interface
1. Plug connector 1b and 4b to their corresponding female parts on the power shell.
2. Put the connector lock bracket UMS-0271 such that the screw holes on the bracket wall is at the same location with the screw holes on connector leg (UMS-0272) wall.
3. Insert screw UMS-0269, the head should be on the connector leg (UMS-0272) side.
4. On the other end of screws, put the nuts UMS-0268 on such that the connector bracket UMS-0271 is mounted to connector leg UMS-0272.
5. Stack ADCS module on Power module
PLD & ADCS module interface
1. Pull the hanging sun-sensor wires from the ADCS module through the reserved holes (shown in the Figure 12) on the PLD lower shell
2. Connect the 10-pins connector to the header of the sun sensor.
3. Stack PLD module on ADCS module, meshing male intermodular connectors 5b and 2b with female intermodular connectors 5a and 2a, respectively
COMS/CDH & PLD module interface
1. Plug connector 3b and 6b to their corresponding female parts on the power shell.
2. Put the connector lock bracket UMS-0271 such that the screw holes on the bracket wall is at the same location with the screw holes on connector leg (UMS-0272) wall.
3. Insert screw UMS-0269, the head should be on the connector leg (UMS-0272) side.
4. On the other end of screws, put the nuts UMS-0268 on, such that the connector bracket UMS-0271 is mounted to connector leg UMS-0272.
5. Stack COMS/CDH module on PLD module
Fasten the vertical torque rod to the POW module using a UMS-0117 screw with Loctite, torqued to 1.35 in-lbf.
Place the Rails and Shells together and place into compression holding jig to keep tolerancing satisfied.
On the +Y face of the satellite; use six UMS-0257 standoff screws and two UMS-0258 screws, both with Loctite applied to bolt the +Y rails to the shells. Torque to 1.13 in-lbf.
On the X faces of the satellite; use two UMS-0258 screws with Loctite to finish bolting the +Y rails to the shells.
Using UMS-0251 screws tightened to 1.35 in-lbf: bolt on the four UMS-0172 solar wing hinge components.
On the -Y face of the satellite; use 12 UMS-0257 standoff screws with Loctite to bolt the -Y rails to the shells. Torque to 1.13 in-lbf.
Inspect the rails to be coplanar at the +-Z faces of the satellite. (insert a link to coplanar inspection procedure).
Inspect the superstructure using the caliper check to ensure the satellite is within tolerance limits. (insert a link to the caliper fit checking procedure).
Assemble -X solar wing subassembly
1. Stack the Solar Panel (UMS-0061) and the backing panel (UMS-0250) together.
2. Mount UMS-0344, UMS-0346, and UMS-0342 to the rear of the stack using UMS-0177 nuts and UMS-0178 screws torqued to 1.13 in-lbf. Ensure Loctite is applied to the screw threading prior to fastening together.
3. Join UMS-0201 and UMS -0214 together using UMS-0177 nuts and UMS-0211 screws torqued to 1.13 in-lbf with Loctite applied to screw threading.
4. Mount UMS-0201 to the rear of the Solar Panel stack using UMS-0177 nuts and UMS-0178 screws torqued to 1.13 in-lbf with Loctite applied to the screw threading.
5. Connect the two UMS-0173 hinge components to the rear of the solar panel using UMS-0177 screws and UMS-0178 screws torqued to 1.13 in-lbf with Loctite applied to screw threading.
Assemble +X solar wing subassembly
1. Stack the Solar Panel (UMS-0348) and the backing panel (UMS-0349) together.
2. Mount UMS-0347, UMS-0345, and UMS-0343 to the rear of the stack using UMS-0177 nuts and UMS-0178 screws torqued to 1.13 in-lbf. Ensure Loctite is applied to the screw threading prior to fastening.
3. Join UMS-0215 and UMS -0216 together using UMS-0177 nuts and UMS-0211 screws torqued to 1.13 in-lbf with Loctite applied to screw threading.
4. Mount UMS-0215 to the rear of the Solar Panel stack using UMS-0177 nuts and UMS-0178 screws torqued to 1.13 in-lbf with Loctite applied to screw threading.
5. Connect the two UMS-0173 hinge components to the rear of the solar panel using UMS-0177 nuts and UMS-0178 screws torqued to 1.13 in-lbf with Loctite applied to screw threading.
Solder FR4 ground plane to the ground wire of COMs coax cable.
Apply loctite to male threading of 6 UMS-0011 screws.
Mount FR4 ground plane to -X face of the satellite superstructure using 6 UMS-0011 screws torqued to 2.0 in-lbf.
Solder wires for +Y-Y solar panels
1. TBD
Place and hold the deployable solar panels on their hinges.
Slide UMS-0176 screws through the deployable hinges while ensuring to add in UMS-0183 springs along the way. See figure for proper spring orientation.
Apply Loctite to the UMS-0176 screw threading.
Screw on the UMS-0179 lock nuts to the UMS-0176 screws with a torque of 1.13 in-lbf.
Mount static solar panels to the superstructure using UMS-0258 screws with a torque of 1.13 in-lbf and Loctite applied.
Weigh the assembled satellite.

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