Tests

Written by: Ricky Gill (Last Updated: 2024-02-13) 

PHASE D: LISSA Dimensions, Payload Integration, Deployer Integration

This test is concerned with verifying that the correctly design LISSA model conforms to drawing specifications required to properly interface with the payload and ISISPACE deployer.  Relevant requirements are summarized below:

• R-LIB-STR-001

• R-LIB-STR-004

• R-LIB-STR-009

• R-LIB-STR-010

• R-LIB-STR-012

• R-LIB-STR-013

• R-LIB-STR-022

• R-LIB-STR-040

• R-LIB-STR-041

• R-LIB-STR-043

• R-LIB-STR-046

• R-LIB-STR-047

• R-LIB-STR-048

• R-LIB-STR-049

• R-LIB-STR-052

• R-LIB-STR-060

• R-LIB-STR-069

• R-LIB-STR-070

• R-LIB-STR-071

• R-LIB-STR-072

Test Description: Measurement of FM structural shells, corner rails, centre rails, 3U solar arrays, solar wings, and payload

Completed: Planned for Phase D

Documented by: Planned for Phase D

Resources Required:

• Tools: Calipers with required precision and accuracy, micrometer, coordinate measurement machine (CMM)

• Hardware and Equipment: TBD. 

• PPE: General PPE.

Verification Activities: All activities related to integration with the payload and deployer will be completed at the end of this test.

Pass Criteria: Pass/fail criteria is determined by drawing tolerances and its relation to the physical FM model of LISSA. 

Test Procedures

Note for all steps: Log each measurement for comparison with engineering drawings.

Part 1

Measure and assemble the primary structure components.

1. Measure the overall dimensions of the FM corner rails using a CMM. 

2. Measure the overall dimensions FM centre rails using a CMM. 

3. Measure the overall dimensions of the FM blank structural shells using a CMM. 

4. Measure or obtain the overall dimensions of the payload using appropriate and controlled measurement/testing facilities. 

5. Assemble the primary structure of LISSA consisting of the module shells, payload, corner rails, and centre rails. 

6. Measure the overall dimension of the FM LISSA structure consisting of the components listed in Step 5 using appropriate/available methods. 

Part 2

Measure, assemble, and integrate the solar arrays and solar wings on the primary structure in Part 1.

1. Measure the overall dimensions of the FM 3U solar arrays and 6U solar wings using a CMM. 

2. Install the 3U solar arrays and 6U solar wings on the primary structure constructed in Part 1 above.

3. Measure the overall dimensions of the structure using appropriate/available methods.

Part 3

Install components which affect the overall dimensions of the CubeSat such as the components required to fit within the extra tuna can volume. 

1. Measure the overall dimensions of the ADCS-CDH module shell modifications required to mount the star tracker. 

2. Measure the overall dimensions of the  star tracker adapter. 

3. Install the star tracker adapter and star tracker in the correction location according to the drawings presented in the ICD section.

4. Measure the overall dimensions of the POW-COM module shell modifications required to mount the GNSS antenna. 

5. Measure the overall dimensions of the GNSS antenna adapter.  

6. Install the GNSS antenna in the correction location according to the drawings presented in the ICD section.

7. Measure the dimensions of the assembled satellite structure relevant to the tuna can volume space. 

Part 4

1. Verify if the assembled satellite structure interfaces with the deployer properly. 

Part 5

1. Measure the mass of the FM LISSA structure when fully assembled.

PHASE D: Component Verifications

This test is concerned with verifying that the structure and all required components are in their correct locations and installed properly. 

• R-LIB-STR-038

• R-LIB-STR-039

• R-LIB-STR-065

• R-LIB-STR-066

• R-LIB-STR-067

• R-LIB-STR-074

• R-LIB-STR-075

Test Description: Physical inspection and verification that all required components are installed and installed correctly.

Completed: Planned for Phase D

Documented by: Planned for Phase D

Resources Required:

• Tools: TBD.

• Hardware and Equipment: TBD. 

• PPE: General PPE.

Verification Activities: All physical inspection activities shall be completed after this test. 

Pass Criteria: Pass/fail criteria is determined by if a component is installed (1) and installed correctly (2).

Test Procedures

There is a pass/fail criteria for each item in the following list based on if it is installed (1) and if it is installed properly (2):

• All fasteners installed and installed according to proper torque specifications.

• The separation switches are installed through the CubeSat feet.

• The RBF switch is installed in accessible location once inserted into the dispenser.

• The thruster nozzle is installed in a direction away from the structure, payload, and star tracker.

• There is a polished aluminum surface that exceeds dimensions of 10 cm x 10 cm. 

• There is a exists a retroreflector on at least one surface of the satellite structure.

• All other components and fasteners can be verified by referencing the assembly drawings in the structure ICD. 

PHASE D: Separation Spring Functional Tests

This test is concerned with verifying that the separation springs can function according to the following requirements:

• R-LIB-STR-020

• R-LIB-STR-023

• R-LIB-STR-038

Test Description: Creating an EM/FM separation spring and verifying that it meets the requirements listed above.

Completed: Planned for Phase D

Documented by: Planned for Phase D

Resources Required:

• Tools: TBD.

• Hardware and Equipment: TBD. 

• PPE: General PPE.

Verification Activities: The separation springs shall be proven to work when interfacing with the deployer.

Pass Criteria: Pass/fail criteria is solely determined on the ability to meet the aforementioned requirements.

Test Procedures

To verify the aforementioned requirements, three tests need to be performed (one test per requirement):

1. Compression of the separation switch mechanism and measurement of reaction forces using load cells.

2. Precise actuation of the separation switch mechanism using a precise linear actuator to measure activation ranges.

3. Integration of separation switch into the satellite structure to test actuation functionality when interfacing with the deployer. 

PHASE D: LISSA Mass Properties Test

This test is concerned with verifying that LISSA has mass lower than what is specified in R-LIB-STR-060 and a center of mass that conforms to requirement R-LIB-STR-073. This test is related to the following requirements:

• R-LIB-STR-060

• R-LIB-STR-073

Test Description: Measuring the total mass and center of mass of LISSA. This is done by using a series of load cells to measure the load distribution of LISSA for different mounting orientations.

Completed: Planned for Phase D

Documented by: Planned for Phase D

Resources Required:

• Tools: Load cells, weighing scale.

• Hardware and Equipment: TBD. 

• PPE: General PPE.

Verification Activities: The mass properties of LISSA shall be verified to conform to deployer requirements and can be used for thruster nozzle alignment.

Pass Criteria: Pass/fail criteria is solely determined on the ability to meet the aforementioned requirements.

Test Procedures

To verify that the total mass is within the limits as outlined in R-LIB-STR-060:

1. Measure the mass of the satellite using a weighing scale.

To verify that the center of mass is within the limits as outlined in R-LIB-STR-072:

1. Measure the mass properties of the satellite along all three axis using a load cell test configuration. 

PHASE D: Solar Wing Deployment Testing

This test is concerned with testing the proposed hold and release mechanism as outlined in (link). This test is related to the following requirement:

• R-LIB-STR-003

• R-LIB-STR-042

• R-LIB-STR-076

Test Description: Quantifying the reliability of developed hold and release mechanism.

Completed: Planned for Phase D

Documented by: Planned for Phase D

Resources Required:

• Tools: Existing EM LISSA model and other related EM components such as solar wings and hinges.  

• Hardware and Equipment: TBD. 

• PPE: General PPE.

Verification Activities: The functionality and reliability of the hold and release mechanism shall be quantified to be within the specifications as outlined in R-LIB-STR-076.

Pass Criteria: Pass/fail criteria is solely determined on the ability to meet the aforementioned requirements.

Test Procedures

1. Refer to (link) for detailed installation procedures. 

2. Test and modify the hold and release mechanism until the desired success rate is achieved in all required operational environments.

ROOM TEMPERATURE

Part 1

Installing the solar wing deployment strings.

1. Cut 2,  12 inch pieces of braided fishing wire.

2. Thread the cord through the hole positioned on the middle of the top surface of the solar wing and tie it to the cross bar adjacent to the hole.

3. While the wings are held closed, thread the free end of the wire under the resistor positioned on the top of the body of the satellite and loop it around the resistor one time. Pull the cord until it is tight. It would be helpful to have someone else hold the wings closed to make this process easier.

4. Thread the free end of the cord through the hole positioned on the middle of the top surface of the other solar wing and tie it to the adjacent cross bar, Make sure that the knot is tight and that the wings are held firmly in the closed position.

NOTE: The process of tying the string to either wing is to be made easier in the revamped design by the addition of a screw in a similar spot to the hole on the top of the wing, which the cord can be attached to and tightened.

5. Flip the satellite upside down and repeat steps 1 through 4 on the other side of the wings.

6. One finished with the cables, place the 3d printed feet on the satellite.

Part 2

Attaching the power source and proceeding with the test.

1. Connect the positive clamp from the power supply to both of the yellow resistor cables using the same clamp.

2. Connect the ground clamp from the power supply to both of the white resistor cables at the same time.

3. Set the power supply to a voltage of 6.4 volts.

4. Turn the power source on and record how long it takes for the wings to deploy.

NOTE: Turn the power source off as soon as the wings deploy to avoid damage to the electronics.

COLD TEST

Part 1

Installing the solar wing deployment strings.

1. Contact the person in charge of the freezer to confirm it is available and set at -30 degrees.

2. Cut 2,  12 inch pieces of braided fishing wire.

3. Thread the cord through the hole positioned on the middle of the top surface of the solar wing and tie it to the cross bar adjacent to the hole.

4. While the wings are held closed, thread the free end of the wire under the resistor positioned on the top of the body of the satellite and loop it around the resistor one time. Pull the cord until it is tight. It would be helpful to have someone else hold the wings closed to make this process easier.

5. Thread the free end of the cord through the hole positioned on the middle of the top surface of the other solar wing and tie it to the adjacent cross bar, Make sure that the knot is tight and that the wings are held firmly in the closed position.

NOTE: The process of tying the string to either wing is to be made easier in the revamped design by the addition of a screw in a similar spot to the hole on the top of the wing, which the cord can be attached to and tightened.

6. Flip the satellite upside down and repeat steps 1 through 4 on the other side of the wings.

7. Take the prepared satellite to the freezer and place inside for at least 24 hours to allow for uniform temperature. 

Part 2

Attaching the power source and proceeding with the test.

1. Connect the positive clamp from the power supply to both of the yellow resistor cables using the same clamp.

2. Connect the ground clamp from the power supply to both of the white resistor cables at the same time using the same clamp.

3. Set the power supply to a voltage of 6.4 volts.

4. Turn the power source on and record how long it takes for the wings to deploy.

NOTE: Turn the power source off as soon as the wings deploy to avoid damage to the electronics.

Solar Wing Test Results:

PHASE D: Vibration and Thermal Tests

This test is concerned with verifying the structural integrity of the satellite under vibration and thermal loading conditions. The following requirements are related to this test:

• R-LIB-STR-002

• R-LIB-STR-062

• R-LIB-STR-063

Completed: Planned for Phase D

Documented by: Planned for Phase D

Resources Required:

• Tools: TBD

• Hardware and Equipment: TBD. 

• PPE: General PPE.

Verification Activities: Listed above.

Pass Criteria: Pass/fail criteria is determined by drawing tolerances and its relation to the physical FM model of LISSA.

PHASE D: Foot Switch Test

This test verifies that the foot switch pins actuate the switches when compressed. The following requirements are related to this test:

• R-LIB-STR-023

Completed: Planned for Phase D

Documented by: Planned for Phase D

Resources Required:

• Tools: Foot switch assembly, multimeter, caliper, switch mount

• Hardware and Equipment: TBD

• PPE: General PPE.

Verification Activities: Listed above.

Pass Criteria: Pass/fail criteria is determined by drawing tolerances and its relation to the physical FM model of LISSA.

Test Apparatus 

Test Procedures

1. Assemble the foot switch components, adjusting the switch position using the screw slots so that, at the uncompressed length, the pin is just short of actuating the switch.

2. Insert the foot switch pins into the holes of the switch mount. Verify that the switches are not activated by checking with a multimeter—there should be no beep when the probes touch the bottom and middle pins.

3. Measure the distance between the mount and the surface of the switch bracket using a caliper. Reconfirm that the switches are not activated.

4. Press down on the foot switch to compress both pins. Using the multimeter, verify that the switches are now activated—you should hear a beep when the probes touch the bottom and middle pins

5. Measure the compressed distance between the mount and the surface of the switch bracket with a caliper.

6. Release the foot switch and allow it to return to its uncompressed position. Verify again that the switches are no longer activated.

7. Measure the resting distance between the mount and the surface of the switch bracket with a caliper.

8. Confirm that the total travel distance of the pins (difference between resting and compressed measurements) is greater than 5 mm.