Dandelions-1

Dandelions-1 is a space mission payload which is going sharing its volume in Waratah seed  satellite mission and Space Machines Company (SMC) Rideshare satellite bus which is part of waratah seed space mission under The university of Sydney. 

Project Details

Mission objective 

Satellites have been playing a crucial role in running space experiments.  This project aimed to study the material properties of biodegradable composites for use in space environment.

The Objective of the project can be further subdivided into a detailed list as follows: 

1. To study the Biodegradable composite material (AMPLITEX) in the  space condition 

a. Gather data in the form of stress ( Loadcell) and strain (Material sample -strain gauge) curve to study its structual properties. 

2. Build capability for the company to execute space projects.

3. Use of the tested material to use in other space applications such as re-entry, launch vehicle structure.

Main Stakeholders

1. Space Machines company, Botany , NSW, Australia - Ride share satellite  bus 

2. Waratah seed Mission, The University of Sydney , Camperdown, NSW, Australia- Ride share satellite bus

3. Bcomp , Fribourg - Switzerland - Biodegradable composites 

4. Nhmicro,Brookvale, NSW- Precision manufacturer

Role and Team Structure 

I served as Mechanical Engineer   for the Dandelions-1 satellite payload  . My main responsibilities included:

1. Preparing CAD models for the Mechanical and thermal management systems using AUTODESK INVENTOR. 

2.  Validation of the Mechanical/structural components to qualify for space environment. 

3. Running  Dynamic structural (MODAL,RANDOM VIBRATION, HARMONIC, SHOCK RESPONSE) simulation on the payload and ensuring the natural frequencies are within the allowable limits as per the launch provider's criteria. 

4. Visiting Flight qualification test centres to perform shake table test( Vibrational) and Thermal vacuum  ( functionality check ) 

5. Procurement  of Materials needed to mount the sub-systems of the payload 

6. Integration of the payload and ensuring that the mechanical components are well within the tolerance limits ( 5 microns). 

7. Design and implementation strain gauge- composite installation to prepare the material samples for data acquisition. 

8. Implementing design matrix ,issue analysis , KPI framework in the workflow for efficient and precise design choices.

Mechanical Design Team members : 

1. Lea Molnar - Lead Aerospace engineer 

  a. Stakeholder management and communication 

b. CAD design and assembly 

c. Project Management

d. Flight qualification test planning 

2. Vidisha - Aerospace Engineer 

 a. Procurement / Supply Chain 

b. Integration 

c. Model Clearance checks 

d. CFD simulation 

e. Pre-processing ANSYS Models. 

Outcome and Accomplishments 

Throughout the course of this project, I have gained valuable skills and knowledge that have helped me develop as a professional. The following are some of the outcomes and achievements that I have attained:

• Successfully Completed the component designs 

I am proud to say that I have successfully completed this project on time and within budget. In the process of designing components , I have implemented various design tools such as FMEA, decision matrix and Issue analysis framework.  Throughout the project, I demonstrated my ability to manage my time effectively and to work efficiently to achieve my goals. This has helped me develop the discipline and resilience required to complete complex projects.

• Demonstrated Expertise in CAD , CAE, Integration ,testing, systems engineering  and manufacturing. 

During the course of this project, I applied my knowledge of mechanical engineer and developed expertise in the following : 

1. CAD modelling with tolerancing to cater the manufacturing flaws. 

2. Design and analysis of the design using Fluid structure interaction which includes real-time simulation of both the CFD and FEA. 

3. Knowledge of " Design of manufacturing"  approach in designing products. 

4. Designing for ease of integration after manufacturing . ( This was mitigated by simplifying the complex models)

5. Test planning for space environments and data interpretation.  

6. Implementation of systems thinking to reduce the redundancy caused by design changes. 

•  Developed Strong Problem-Solving Skills for space Environment

Throughout the project, I encountered several challenges that required me to use my problem-solving skills. I was able to identify the root cause of the problems and develop effective solutions to address them. This has helped me develop the ability to approach complex problems with a strategic mindset.

• Improved Communication and Collaboration Skills

Collaboration and communication are critical skills in any project. Throughout this project, I collaborated with different stakeholders, including team members, clients, and vendors. I effectively communicated with all stakeholders to ensure that everyone was on the same page, and this has helped me improve my communication and collaboration skills.

• Produced High-Quality Deliverables

Throughout the project, I produced high-quality deliverables that met the project requirements. This has helped me develop the attention to detail required to produce work that meets the highest standards. Some of the deliverables are : 

a. Detailed report to make justification for the design changes made. 

b. Presented High fidelity simulation models for better realization of the test environment of the satellites. 

c. Used space rating material selections approach such as outgassing & cold welding data. 

d. Lead the cross team (electrical and mechanical ) integration as a representative of the mechanical team. 

e. Implementing systems thinking approach to reduce redundancy of engineering costs. 

f. Ensured that the Payload passed the functionality & vibrational test by validating the design before the test using Finite element analysis approach. 

• Gained Valuable Experience

Through this project, I gained valuable experience that has helped me grow as a professional. I developed my project management, problem-solving, communication, and collaboration skills. This experience will be invaluable as I move forward in my career. There were instances where I would take leadership of the projects in the absence of the management. The project was a great learning experience to explore the avenues to execute a space project commercially. 

In conclusion, I am proud of the outcomes and achievements that I have attained through this project. I am confident that the skills and experience I have gained will help me succeed in future projects and in my professional life.

 Detailed Design 

Design 

Dandelions-1 is a experimental payload which is aimed at testing the strain properties of the composite material (bio-degradable)  in the space environment. The system consists of enclosure with the experimental setup in the enclosure and PCB which runs the experiment. The payload is meant to on board CUAVA and space machines company satellite on the orbit. The rendered CAD model has been shown in the picture below. 

Analysis 

The ride share payload had some critical requirements for its survival in launch conditions due to the setup of the experiment. In order to verify that , I had run simulations on the payload using  ANSYS Workbench . Steps implemented for the modelling of the payload are:

1. Simplification of the geometry using SPACE CLAIM to focus on the major failure modes in the Assembly. 

2. Preparing Pre-stressed models( static structural)  considering the Bolt-pretension that actions on the payload assembly. 

3.  Preparing Modal Analysis module to determine the Eigenvalue Frequency (natural frequency) of the system to know the  resonance point. 

4. Running Random Vibrations  based on the Modal analysis run previously along different axes( X,Y,Z axis)

• This approach simulates close enough conditions to the shake table test approach. 

5. Harmonic vibrations study based on the Launch Providers data

6. Shock vibrations  model to test the maximum frequency during failure. ( Response Acceleration) 

7. Quasi-static Simulation model to check the ability of the payload to survive the high G forces. 

Manufacturing 

The manufacturing the of payload was carried out using precise CNC machining process . The design of the components were made considering the factor " Design For Manufacturing ". This approach solves many  issues when it comes to manufacturing . 

Tolerance: 0.005 mm 

The manufacturing of the payload was carried out considering the following factors: 

• The tolerances was of the utmost priority so that the integration can be made smooth. 

• The material selection was also important to avoid phenomenon such as uneven  "Thermal expansion of metals" , "cold welding" and "outgassing properties".  

• The parts of the system had to be well within the weight constraint. 

• The Quality assurance process of the manufacturer was discussed and the suggestions were made based on the manufacturing flaws that we encounter. 

Integration 

The payload consists of two major systems which are Electronics and Mechanical. The Design of the payload was carried out using Design For Integration approach. The design approach included the design considering to check the impact of the change on other systems. This approach reduced the integration time significantly.  

The assembly of the payload was fairly simple with focus on mounting the components rigidly to the enclosure.  For the printed circuit board  and the enclosure , the following factors were considered: 

• Manufacturing Tolerance of the parts were  considered in the design to mitigate the  fitment issues and interference. 

• The placement of the electronic components such as (CPU, transistors, Inductors) was carried out in a way that it interfered with the mechanical systems. 

• Cross team collaboration to ensure the design changes are being updated to the other departments.

For the integration of the payload in to the rideshare satellite bus, the following factors were considered: 

• Manufacturing tolerance of the mounting holes was made exactly as the test rig to avoid fitment issues in to the satellite. 

• The dimensional constrained that was given to us for our payload was considered and the height, width and length of the payload were all made to fit that constraint. 

Outcomes: 

• The assembly of the payload was smooth without interference. 

• The payload integrated well with the ride share satellite bus. 

Achievements:

• Implementation of Design for Manufacturing & Integration approach . 

• Cross team collaboration to ensure the systems functions as as one entity. 

• Systems thinking approach in the project execution. 

Testing (TVAC & Shake Table)

The payload has gone through two types of tests which are mainly: 

1. Vibrational testing : 

The vibration test for the payload which would be  ride CUAVA mission was carried out in the Advanced Instrumentation Technology Centre (AITC) , Mt. Stromlo, Canberra.  I and my other colleague visited the AITC , Mt. Stromlo , Canberra with the CUAVA Team to monitor the Shake test for our payload representing (Dandelions).  The Shake test was quite an experience in terms of learning the actual process of flight qualification and gave an insight in to structural dynamics for space environment. 

Outcomes of the test : 

• The vibration profile of the random vibration tests were somewhat closer to the response profile of the payload. 

• The payload passed the vibrational qualification test to be launched in to space. 

Achievements : 

• I had a great practical learning experience to understand the things to consider when designing a space payload. 

• Developed ability to model the simulations to align with the testing procedure in real life. 

2. Temperature cycling Test: 

The  thermal cycling test ( TVAC) test for the functionality test was carried out at UNSW , Sydney. For the test , the whole team was responsible to take shifts for making sure the test data is not lost in process.  The primary focus of the test was to check the functionality of the system in the fluctuating temperatures of the space environment. 

Outcomes of the test:

• The test was a success  as the payload was responsive at all the temperature cycles. 

Achievements:

• It was a great learning experience , due to the fact that the we could practically check the fucntionality of the payload.