Final Design Report UV Imager Application for a Cube Satellite Sponsor: UC Berkeley - Space Sciences Laboratory 2018 Senior Project Team: Jason Grillo - [email protected] Troy Hajjar - [email protected] Brady Hill - [email protected] Project Advisors: Eltahry Elghandour – Cal Poly Thomas Immel – UCBSSL Kodi Rider - UCBSSL Table of Contents Table of Contents ....................................................................................................................... 2 List of Figures ............................................................................................................................ 4 List of Tables.............................................................................................................................. 7 Abstract ...................................................................................................................................... 8 Chapter 1: Introduction .............................................................................................................. 9 Chapter 2: Background ............................................................................................................ 10 Chapter 3: Scope of the Senior Project .................................................................................... 16 3.1 Primary Focus ................................................................................................................ 16 3.2 Secondary Focus ............................................................................................................ 17 3.3 Customer Needs and Wants ........................................................................................... 18 Chapter 4: Concept Design Development ................................................................................ 21 4.1 Fixed and Free Design Functions .................................................................................. 21 4.2 Brainstorming and Ideation ............................................................................................ 23 4.3 Early Prototyping and Idea Refinement ......................................................................... 24 4.4 Modeling the Chosen Concept ....................................................................................... 30 4.4.7 Preliminary Experiments ............................................................................................ 40 Chapter 5 – Final Designs ........................................................................................................ 42 5.1 Overall Description of Designs ...................................................................................... 42 5.2 Detailed Design Descriptions ........................................................................................ 45 5.2.1 Optics Assembly ......................................................................................................... 45 5.3 Analysis Description and Results .................................................................................. 50 5.4 Explanation of Material, Geometry, and Component Choices ...................................... 61 5.5 Cost Analysis ................................................................................................................. 64 5.6 Safety ............................................................................................................................. 72 Chapter 6 – Manufacturing, Assembly, and Integration .......................................................... 73 6.1 Procurement ................................................................................................................ 73 6.2 Manufacturing ............................................................................................................ 73 6.3 Assembly .................................................................................................................... 75 6.4 Lens Assembly and Bonding ...................................................................................... 77 2 6.5 Issues and Changes ..................................................................................................... 79 Chapter 7: Design Verification Plan ........................................................................................ 82 7.1 Boresight Alignment Verification Plan ......................................................................... 83 7.2 Average Spot Size Verification Plan ............................................................................. 83 7.3 Field of View Verification Plan ..................................................................................... 84 7.4 Stray Light Rejection Verification Plan ......................................................................... 85 7.5 Testing Sequence ........................................................................................................... 86 7.6 Preliminary Instrument Images ...................................................................................... 86 7.7 Thermal Vacuum Testing .............................................................................................. 89 7.8 Vibration Testing ........................................................................................................... 93 7.9 Verification of Lens Assembly Model through FEA ................................................... 103 7.9 Summary of Instrument Performance .......................................................................... 112 Chapter 8: Project Management ............................................................................................. 116 8.1 Milestones .................................................................................................................... 116 8.2 Work Planned after PDR ............................................................................................. 117 8.3 Work Planned after CDR ............................................................................................. 117 8.4 Quarter 3 Completed Work and Milestones ................................................................ 117 Chapter 9: Conclusions .......................................................................................................... 118 9.1 Statement of Work: Chapters 1-3 ................................................................................ 118 9.2 Preliminary Design Review: Chapters 4 & 7 ............................................................... 118 9.3 Critical Design Review: Chapters 5-7 ......................................................................... 118 9.4 Final Design Review: Chapter 7 Continued ................................................................ 119 References .............................................................................................................................. 119 Appendices ............................................................................................................................. 120 Appendix A – QFD House of Quality ............................................................................... 122 Appendix B – Customer Requirements Spreadsheet ......................................................... 123 Appendix C – Ray Trace Diagram..................................................................................... 126 Appendix D – Preliminary Analyses and/or Testing Details ............................................. 127 Appendix E – Concept Layout Drawings .......................................................................... 129 Appendix F – Safety Hazard Checklist / FMEA ............................................................... 134 Appendix G – Gantt Chart ................................................................................................. 138 3 Appendix H – Preliminary Analyses and/or Testing Details ............................................. 139 Appendix I – Complete Drawings Package ....................................................................... 187 Appendix J – Budget/Procurement List ............................................................................. 188 Appendix K – Design Verification Plan Table .................................................................. 194 Appendix L – UVI Cube Operator’s Manual .................................................................... 196 Appendix M – UVI Cube Thermal Vacuum Test Procedure ............................................ 197 Appendix N – UVI Cube Vibration Test Procedure .......................................................... 198 Appendix O - Field of View Uncertainty Propagation ...................................................... 199 Appendix P – Lens Bonding Procedure Outline ................................................................ 200 List of Figures Figure 1. Comparison of a standard 1U CubeSat to a human hand [5]. Figure 2. Diagram of the inside and outside assembly of the Heritage Instrument FUV [7]. Figure 3. DSCOVR mission patch showing the satellite’s complex size and shape [10]. Figure 4. A typical P-POD CubeSat deployer [4]. Figure 5. The Heritage Instrument FUV Turret Cover that mechanically opens after the first spacecraft outgassing [6]. Figure 6. The MIGHTI instrument lens assembly with associated mount, encapsulant, keeper, and datum surface [3]. Figure 7. Boundary sketch of the Front Optics Assembly Figure 8. Design function schematic of the 1U optical assembly. Figure 9. First prototype of the optics assembly