Full Assembly Vibration Test Plan
Introduction
Test Description: The full assembly vibration test will be used to certify that the satellite is suitable for launch. A reduced functional test will be performed after the vibration test to ensure that the electronics function as intended. The satellite will also undergo a visual inspection, with particular attention to fasteners backing out, checking whether deployable systems are intact, and checking whether cracks have formed on the solar arrays.
Revision 1:
Revision 2: October 18, 2022 by Ali Barari
Revision 3: March 7, 2023 by Ali Barari
Resources Required:
Tools: Camera, Pens and Paper, Flashlight, Torque wrench, Kapton tape
Hardware and Equipment:
Nanoracks Mock Deployer (Will be provided by Nanoracks/CSA)
Seco SafeCell Anti-Static Bubble Wrap (Will be provided by Nanoracks/CSA)
Zotefoam Plastazote Foam (LD45FR) (Will be provided by Nanoracks/CSA)
Husky Ratchet Tie-Down Straps (FH0942) (Will be provided by STARLab)
Eye Bolts or Hoist ring (Will be provided by STARLab or test facility)
ESD matt (Will be provided by STARLab)
ESD wrist band (Will be provided by STARLab)
Table (Will be provided by test facility)
Allen keys (Will be provided by STARLab)
Gloves (Will be provided by STARLab)
Kimwipes and isopropyl (Will be provided by STARLab)
PPE: Hearing Protection, Approved Steel-toed Shoes, Approved Safety Glasses
Verification Activities:
Pass Criteria:
The satellite must not have any fasteners back out, deploy any deployables, crack any solar arrays, or break internally or externally in any way. Configuration must NOT be broken post vibe test.
If anything needs to be modified or deployed post vibe test, a waiver or penalty vibration test is necessary. Contact NR to receive PASS/FAIL assessment.
Nanoracks Soft-Stow Vibration Test Configuration
UUT: Nanoracks CubeSat Deployer (NRCSD)
Flight-equivalent bubble wrap & foam layered above and below
Strapped to table via eye bolts or similar hardware
One (1) accelerometer (tri-axis if available) on NRCSD
One (1) control accelerometer on shaker table
Shaker table surface area required for NRCSD:
Fig 1: Required vibration table surface area.
Vibration Test Axes
Fig 2: Vibration test axes
Nanoracks Soft-Stow Vibration Test Levels
Soft-Stow Configuration Step by Step
Integrate CubeSat into the Test Pod
Move the Test Unit to the shaker table
Check to make sure the technician has the appropriate profile loaded into the software
Determine first test axis (X, Y, or Z)
NOTE: if test pod or CubeSat cannot be rotated in between axis, a vertical expander head may be necessary to get the final axis
Place down Zotec Foam in the center of the table in the determined first axis
Place down the anti-static bubble wrap (1 or 2 layers)
Place the test unit on the bubble wrap
NOTE: Ensure the RBF face is facing the +Y axis.
NOTE: because the set up is not inherently centered, ensure the unit is in the center of the table, or center of the bolt hole pattern on the slip table
NOTE: If any accelerometers plan to be placed on the Test Unit, now is a good time to do that
Place anti-static bubble wrap on the top of the test unit
Place Zotec foam on the top of the bubble wrap
Install eye bolts or hoist rings (depending on the size of the unit, 4 or 6 may be necessary)
NOTE: ensure the Test Unit is centered between the eye bolts
NOTE: test lab may have these items, or they may need to be provided. Check with lab on bolt hole sizes and availability of hardware prior to arrival for the test. Test Lab will also be able to identify torque specs for the eye bolts/ hoist rings
Use ratchet straps (2-3, depending on number of eye bolts) to restrain the Unit
Tighten rachet straps till two fingers have trouble slipping underneath the straps on the top of the unit
NOTE: the tighter the better. If you are concerned with amount of slack in the line, tighten further.
Ensure unit is stable and all straps are tightened. Slack line from the straps should be restrained
Run first Axis of vibration test
After test, ensure straps are still tight. Also ensure all fasteners and components of the test pods have not come apart
Breakdown the set up and repeat for next two axes.
Fig 3: NRCSD setup with bubble wrap and foam layer
Fig 4: Final setup for the vibration test
Post-vibration Test Procedure
Unpack the satellite from the deployer once it has been vibrated in each axis.
Inspect for damage to the deployment mechanisms and thermistors.
Inspect that the deployments have not deployed.
Inspect for any loose external fasteners
Inspect for any visible cracks in the solar panels
Inspect for any other forms of breakage to the satellite
Should any of the inspections fail, the satellite must be torn down and reassembled with fresh components that address the failed inspection.
Conduct the reduced functional test if inspections are passed.
Nanoracks Requirements for the Vibration Test Report
The Vibration Test Report shall contain the following:
Title containing the name of the CubeSat
Photos of each configuration (axis) of the test
An overview of the NR vibration testing requirements
The intended test profile and configuration (Soft Stow VS Hard Mount)
The as-run profile response from the control accelerometer for each axis
OPTIONAL (but preferred):
Photos of the satellite pre and post test de-integrated from the test pod
A conclusion stating the satellite was inspected and turned on post vibe test and everything works as expected