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2000785 Rev D User`s Manual for Mark II Lightband

1. 88 21 STANDARD EIGHTBAND DELIVERABLES 02 Dese ct uve Ova eo ceo vee spese iv sa vea eve ee edu ceca isa DRE qve escent EN T 88 21 2 EIGHTBAND 5 TEP PILES woot odo necu re vts A A RU eat un ec TR orn oil a E 89 21 3 ASSEMBLY DRAWINGIS al i E E Di sw ES Ere LM ADEL Ri AM cra 89 FINITE ELEMENT MODELS TEIGHIBANDS S i cured epu ante n e LLL uu 89 22 PURCHASING A LIGHTBAND 2 1210 vane a ed de uae us Cos es aes eb ue eo Gau as Moo cds de eae us Cus vs cea eon cv ea Cora e e ecd de un ev es oo es cae derer eo eee 90 23 LIGHTBAND TRAININGGC 91 24 PACKING SHIPPING AND UNPACKING METHODS 92 25 STORAGE REQUIREMENTS 3 47 3 o coe es do aeuo eoa Cope SE ee s Eo E Sce CE aoc eo UE eee ee ees ee eee ce ee eco 93 26 PROCEDURES DOCUMENTS AND PUBLICATIONS 94 27 B ONERE TERNI NT TY ERR SEN COUNT E 95 28 CG SS RY sree EMEN ERU 96 29 ACKNOWLEDGEMENTS 3 1 2 ee aa a aa aa a
2. a airh Edah E Aua ENES i 97 10 July 2014 www planetarysys com Page 3 of 97 2000785E User s Manual for Mark II Lightband Planetary Systems Corporation 1 Revision History Written Released EST 14 Sep 07 Initial release 02 May 08 at RH RW Added Note on first page MW AZ Added warranty Added flight history Added description of manufacturing process Added discussion of features on adjoining structures Changed standard payment schedule Added customization schedule Added more detail showing how the Lightband works specifically the Motor Bracket assembly Increased the stay out zones by as much as 0 12 inches Added discussion of joint compliance Discussion of features in structures adjoining the Lightband Added description of manufacturing process Added detail of shuttle missions to Thermal section Decreased the font Added detail of Advanced Lightband controller Added detailed description of the standard acceptance tests Added energy for electrical operation Maximum number of Separation Springs is now 24 Minimum number of Separation Springs is six 6 Added success criteria for Lightband test Added detail on isolation systems Added detail of integration procedures 01 Aug 09 AZ MW Updated flight history RH Added correct pictures showing Separation Connectors Increased Separation Spring energy E Added Lightband simulator to GSE Added metallic retaining chord was a polymer Updated flatness require
3. c c 33 5 17 Beare te ri mM M nA c ML M I MEM du MR E uL Rd 33 5 18 MATERIALS AND SURFACE TREATMENTS e itr raum babet cutn debtor te Doo eee s bbc occi en sane tek eee cod echt ace tas 34 5 19 PARET MARKING ee hts acta el hc 35 5 20 SUBESTSTEM VUBIGHI ES Hone casui 35 5 21 COMPONENT SPRING PARAMETERS ccccececececcecececececcececucueaunececscauauaesecacauaunesersceuaunenecseaeaunetstsuauaunererseauaeuaunesscscauauaersrscetsenensneneuaenes 36 5 22 ROTATION RATES SEPARATION VELOCITY AND SEPARATION SPRINGS 37 6 ELECTRICAL PROPERTIES aici iiie E rue ice voee Eo Core eire aene EE Po Vi E ELT ee d Vi IE D AL EIL eats 41 SCHEMATICS ERE 41 6 2 ODHE MOTOERCBRACRETASSEMBIESS i sa EI E EI E CE I At E rU EIE 42 6 3 WIRINGHARNESS DESIGN hesse aa aa a a i a a aa a a a a aaa aa i aiai Sie 43 54 SEPARATION ELECTRICAL CONNECTORS airo Ie sete ve pe a E 44 6 5 OP ARAT ON OM O E O a 45 6 6 VOLTAGE CURRENT AND DURATION OF LIGHTBAND OPERATIONS cccssen RI RII e e Renee nee rhen he
4. Survey SS B Run 025 11 14 2007 2 50 55 PM Survey Post Run 031 11 14 2007 5 04 38 100 Frequency Hz 5 8 Joint Compliance The compliance of the bolted joint from the Lightband to adjoining structures can have a substantial effect on the overall stiffness The stiffness reported in Table 5 1 does not include joint compliance Table 5 3 shows the normalized results of a study of stiffness for a specific Lightband program and illustrates that joint compliance reduces stiffness in all directions The data comes from the test of a 38 810 inch diameter Lightband and is for example rather than design purposes It can be assumed that the effect of joint compliance on any size Lightband is the same as shown in Table 5 3 Normalized Normalized Normalized amp Zip Axis Ry Rotational Stiffness Ry or Rz Rotational Stiffness Stiffness Normalized Axis Stiffness compliance Lightband with joint Table 5 3 The effect of joint compliance on stiffness Source PSC Document 3000233 3 Source Moog CSA Engineering Document 20008507B and PSC Document 20005414 10 July 2014 www planetarysys com Page 22 of 97 2000785E User s Manual for Mark II Lightband Planetary Systems Corporation 5 9 Discussion of Features on Adjoining Structures In order to maximize the stiffness of the satellite stack including the Lightband engineers should design robust featu
5. ais of 4i axis via bi fi artorsio nal pendulum Verify th ati inertia CAD model predicted value method within tolerance If not correctissue orreconfigure and redo acceptance trials Post TestAnalysis 9 Analysis Predict an orbit V with test data and inputs Optional for PostTestCustomerAnalysis Customer Qut af test scope I D nno lx _ el N i a Analysis out of test i Customer can correlate a 12 DOF model to results and create higher fidelity on I orbit predictions beyond the measuring pability of this testfixture l L Figure 15 7 Nominal separation reliability test flow 10 July 2014 www planetarysys com Page 74 of 97 2000785E User s Manual for Mark II Lightband Planetary Systems Corporation Time to Pitch Roll Initiate 2 XLB sec deg s deg s deg s File Trial Cfg Nane 1 1 deploy 001 6 A amp B 28 0 28 204 28 281 2 539 2 441 0 056 0 265 1 066 0 990 1 279 4 89 049 1 500 1423 1399 2 2 deploy 002 6 A amp B 280 28 170 28 213 2 455 2 730 0 056 0 292 1 149 0 739 1 277 4 88 0458 1 503 1423 1392 3 3 deploy 003 6 A amp B 28 0 28 183 28 179 2 563 2 448 0 053 0 279 1 585 0 581 1 280 4 90 0 459 1507 1423 1390 Acceptance ENS HABEN CEREREM ee ON Sp Dra ok Se M
6. 2002317Rev 23 LightOrange Dark Orange 530 66 2002246 RevA 15 LightGreen Dark Green 68 68 2000855Rev 11 LightBlue DarkBlue 111 1 00 06 2002076RevC Figure 8 2 Nominal shock response time history from the Lightband separation 25 Source PSC Document 2002258 10 July 2014 www planetarysys com Page 55 of 97 2000785E User s Manual for Mark II Lightband Planetary Systems Corporation A C o pl co o lt 1 000 Frequency Hz Shock Response Spectrum shock from Lightband Upper Ring 31 LightRed DarkRed 845 1 00E 06 2002317 Rev 23 lt Light Orange Dark Orange 530 66 2002246RevA 15 LightGreen Dark Green 68 68 2000855Rev Figure 8 3 Nominal shock response spectrum from the Lightband separation 26 Source PSC Document 2002258 10 July 2014 www planetarysys com Page 56 of 97 2000785E User s Manual for Mark II Lightband Planetary Systems Corporation 1 000 Frequency Hz shock Response Spectrum Upper Ring Figure 8 4 Nominal shock response spectrum at the Upper Ring interface for an MLB31 600 Note that in Figure 8 4 a fixture mode is present at around 1 050 Hz This mode explains the 5X amplitude resonance Acceleration g NF 1 000 Frequency Hz Shock Response Spectrum Lower Ring Figure 8 5 Nominal shock response spectrum at the Lower Ring interface for an MLB31 6007
7. 2000785E User s Manual for Mark II Lightband Planetary Systems Corporation 3 Why Choose Lightband The Lightband has many advantages over competing products 1 puo qu Qr cus arn 10 11 A Technology Readiness Level 9 rating TRL 9 is the maximum attainable level of this measure which is used by US Government agencies to assess the maturity of evolving technologies Test verifiability Each Lightband goes through environmental testing before delivery to prove separation capability on orbit Lightweight The Lightband is about one third of the weight of a typical clamp band Low height About one half of the height of a typical clamp band Non pyrotechnic The Lightband generates no debris upon or after separation Low shock The Lightband generates very low shock relative to other separation systems All inclusive product The Lightband is delivered with Separation Springs Switches and Connectors included within its assembly and does not require additional brackets No consumables Motor driven eliminating the need for refurbishment or consumable initiators Pyro pulse compatible The Lightband can be separated via a pyro pulse signal Flight heritage Flight proven over 40 times Simplified procurement The Lightband is priced on GSA schedule to streamline procurement 10 July 2014 www planetarysys com Page 11 of 97 2000785E User s Manual for Mark II Lightband 4 Lightband Flight History No Lightband has ever failed
8. 27 Source PSC Document 2002258 28 Source PSC Document 2002258 10 July 2014 www planetarysys com Page 57 of 97 2000785E User s Manual for Mark II Lightband Planetary Systems Corporation 8 2 Maximum Shock Applied to the Lightband Previous testing has provided the maximum shock applied to the Lightband as shown in Figure 8 6 and Figure 8 7 The Lightband was exposed to this shock input 3 times in each of the 3 Lightband axes In all but one trial data was acquired at least 100 000 samples per second The shock response spectrum was computed with 1 6 octave band frequency intervals and 5 damping from 100 to 10 000 Hz No detrimental yield or damage was found on the Lightband upon the completion of these shock trials 100 000 Upper Tolerance Test Level Lower Tolerance E 5 o o c 14 x o o 1 000 Frequency Hz Figure 8 6 Maximum shock environment applied to the Lightband Shock Response Spectrum 3 4 Test Level Upper Tolerance 338 25 25 997 11 943 11 943 16 870 16 870 Figure 8 7 Maximum shock applied to the Lightband in table form 29 Source PSC Document 2002081F 10 July 2014 www planetarysys com Page 58 of 97 2000785E User s Manual for Mark II Lightband Planetary Systems Corporation 9 Selecting a Lightband When selecting a Lightband PSC provides the customer with a document called the Product Build S
9. 12 Strength Test Optional Both28 Shock Test Optional Both 28 p a __ Tota _ j 0 26 JX Table 15 1 Initiation voltages during or immediately following test File g Psc svr0 1 Server 3 Production STP SIV I p Cut Off ug summary File PLightband OperationsYibe Testdeploy 001 lvm Voltage Profile Current Profile Power Profile Energy Profile m Displacement Profile Tip Off Profile Sep Signal Advanced aroo Circuit Channel A Current V TU Channel B Current E Draw Duration sec 2 300 10 064 064 2 100 Time to Separate sec 1 144 eid EN ee gemeres age 199 L ILI IT 39 1 RENI ENT URN E a ZEN a E e a a a a se a sername em 8 Eros E 14007 1 Bx a i 0 994 1 100 AH SIE 1 000 t Channel B Energy Ul A 0578 n At _ fF Channel A Peak Power 0 700 1 X m e Channel B Peak Power 59 851 0 500 0 400 0 169267 0 300 Roll Rate deg sec 0 200 0 234625 0 100 F
10. 60 0150 097 oss 167 15180 1232 Table 16 1 Previous qualification test vibration limits of MLB15 000 Overall 14 78 X Y Z po _ T MaxGmBandwdth HZ 20 NBEToerme H oo 0 gt Control Accel Crosstalk Upper Limit Gms Imaxsinputlevel Random vibe DOF per channel Table 16 2 Qualification random vibration test parameters of MLB15 000 10 00 i ASQ GHz poc poene R S xni ERE 10 100 1 000 10 000 Frequency Hz Figure 16 1 Random vibration profile of qualification test of MLB15 000 10 July 2014 www planetarysys com Page 79 of 97 2000785E User s Manual for Mark II Lightband Planetary Systems Corporation 16 1 2 MLB38 810 Vibration Qualification Test Tested vibration limits of a 38 81 inch diameter Lightband are shown in Table 16 3 Table 16 4 and Figure 16 2 The Lightband operated nominally after completion of test WARNING These vibration levels should not be applied to the Lightband when the Lightband is supporting a substantial mass without carefully considering the effects of resonance and structural impedance The prescribed environment below is for the Lightband alone When the Lightband is supporting a structure engineers must determine how the vibration environment will generate line loading and how much of
11. Current Motor B Voltage Motor A Voltage Motor B Voltage V oO y uaua Voltage V y usun 28 0 140 1 te Current Motor A Current Motor B Voltage Motor A 54 0 5 C Voltage Motor B 0 00 0 05 0 10 0 15 O20 025 03 Time sec 15 1 0 00 0 25 0 50 075 100 1 25 1 50 Time sec e SET FOR FLIGHT Switch state prior to DEPLOY aperatian Circuit t DEPLOY the Lightband initiate separation Figure 6 2 Schematics to stow set for flight and deploy 6 2 The Motor Bracket Assembly The Motor Bracket Assembly is the initiator of the Lightband Providing it with sufficient power will cause separation of the Lightband when the Lightband is stowed The DB 9 socket connector is permanently fastened to the Motor Bracket Assembly The Motors are DC brush precious metal commutation They contain permanent magnets The manufacturer is Maxon Motors US and the part number is RE16 118686 A version of this motor is used to operate the Martian Rover Sojourner The Motors are physically connected to each other via bevel gears Both should be simultaneously powered to induce Lightband separation However one motor alone will power the Lightband to cause separation as a redundancy mechanism Stowing the Lightband shall only be performed by powering both Motors because the stowing process requires more power than
12. Removal from adjoining structure procedure Horizontal integration procedure if applicable Mission assurance verifications Customized discussion of mission integration details to improve efficiency Any other topics desired by the customer www planetarysys com Page 91 of 97 2000785E User s Manual for Mark II Lightband Planetary Systems Corporation 24 Packing Shipping and Unpacking Methods PSC Document 2000827 Procedure to Pack and Unpack Mark Il MLB defines the methods to pack and unpack the Lightband from its shipping container Description The Lightband is shipped in the deployed state Stand offs are used to hold the Upper and Lower Ring separated The Lightband is prepared for shipment Each Lightband is shipped in custom designed protective case dedicated for that particular unit The rugged case is reusable The Lightband is wrapped in two bags Desiccant packs are placed in the inner bag Orientation of the Motor Bracket is marked on the outside of the bags Composite foam shapes encapsulate the Lightband inside its case The case is sealed with Lightband and documentation inside The contents are indicated on the outside of the case The shipping service is FedEx Next Business Day Shipping weight varies by Lightband size Customer receives Lightband and unpacks IAW with PSC Document 2000827 Procedure to Pack and Unpack MLB Table 24 1 Packing shipping and unpacking method 10 July 2014 www planeta
13. Time min R01 Motor A T01 Lower Ring T02 Upper Ring Figure 7 2 Data record from a nominal thermal vacuum test P lt 10e 5 Torr 21 Source PSC Document 2002305 22 Source PSC Document 2002303 10 July 2014 www planetarysys com Page 53 of 97 2000785E User s Manual for Mark II Lightband Planetary Systems Corporation 7 3 Absorptivity and Emissivity The materials in Table 5 9 show the surface treatments of the Lightband components They may not be modified by the addition of paint or tape because there is no area to apply such treatments Specific measurements of thermal optical absorptivity and emissivity of the Lightband have not been performed as they are highly dependently upon variations in surface finish For the clear hard anodize of the Lightband Upper and Lower Rings PSC defers to industry accepted range for these values given in multiple sources Characteristic Solar Absorptivity a 0 27 to 0 35 Emissivity 0 76 to 0 84 Table 7 1 Absorptivity and emissivity ranges Customers have occasionally inquired about the possibility of black anodizing components of the Lightband for the purpose of thermal balancing The only components that can be black anodized are the Upper and Lower Rings Typically though black anodizing these parts is not worth doing because masked areas make up a substantial fraction of the total exposed area Additionally subsystems such as Sepa
14. section view 10 July 2014 www planetarysys com Page 13 of 97 2000785E User s Manual for Mark II Lightband Planetary Systems Corporation zn shear Pin Spring Plunger 3x per Leaf 1x per Leaf Sliding Tube in Deployed Position Hinged Leaf Assembly Figure 5 3 Lightband in the deployed state also referred to as separated 10 July 2014 www planetarysys com Page 14 of 97 2000785E User s Manual for Mark II Lightband Planetary Systems Corporation 5 2 How the Lightband Works Videos showing the Lightband operating on the ground and on orbit are available at www planetarysystemscorp com Figure 5 4 shows the Lightband in the stowed state The Retaining Ring is in compression black arrows pressing the Leaves outward into the Upper Ring The Links are over centered and the motors are not powered Over Centered set for flight Over Center Angle Ad X Figure 5 4 The Lightband in the stowed state top view Figure 5 5 shows the Lightband the initiated state Upon deployment initiation the motors are powered causing the mechanism to instantly 70 075 seconds snap inward allowing the Retaining Ring to contract Retracted deployed Figure 5 5 The Lightband in the initiated state 10 July 2014 www planetarysys com Page 15 of 97 2000785E User s Manual for Mark II Lightband Planetary Systems Corporation The metallic Leaf Retaining Cord provides a constant radial force inward that causes all the
15. In flight lateral loads tend to make the greatest contribution to line loading Maximum lateral load and axial load do not occur at the same time and standard PSC strength testing reflects this fact Note that PSC documentation often expresses line loading in terms of force Leaf instead of force bolt Lightbands naturally have 1 less Leaf than bolt but it is assumed that the difference in line load value from this computation method is trivial Thus the terms force Leaf and force bolt are interchangeable Maximum axial line load is given by Equation 1 p 4VCMx 1 eq 7 D 1 Where Peg is maximum axial line loading force per bolt Fx is axial force force n is the number of fasteners in the bolt circle n is one more than the number of Leaves V is lateral force force is the distance from the Lightband origin to the load application point in the x direction length D is the bolt circle diameter length Maximum shear line loading is given by Equation 2 Q v7 2 Where Q is the maximum shear line load force per bolt V is the lateral force force n is the number of fasteners in the bolt circle n is one more than the number of Leaves D is the bolt circle diameter length Mx is the maximum applied torsional moment about the X g axis Typically negligible in flight loading The values in Table 5 6 were calculated by applying loads produced by Equation 1 and Equation 2 to a Lightband in strengt
16. Isolation System Vertical Integration Horizontal Integration Transition ring or other Spring rigid structure for PE compliance stiffness while stowing recommended Extremely difficult to access Spring damper of Space Remarks fasteners from isolation system FR vehicle Lightband to adjoining vehicles LULA Upper Ring i y am Final stage of Lower Ring launch vehicle Figure 10 1 Typical vertical and horizontal integration methods Vertical integration allows the weight of the space vehicle to compress the Separation Springs Horizontal integration requires the capacity to compress the Separation Springs such as a clamp that straddled the space vehicle PSC manufactures proprietary Lightband Compression Tools that can be used for this purpose as well See Table 20 1 Isolation systems simplify integration because they remove the need to stow the Lightband in the field alleviate flatness requirements and add compliance to the system Transition Rings can be used to simplify integration See Section 20 10 July 2014 www planetarysys com Page 62 of 97 2000785E User s Manual for Mark II Lightband Planetary Systems Corporation The compliance of the entire stack needs to be assessed in order to properly integrate the Lightband When the Lightband is stowed as part of the integration process the whole system will be structurally indeterminate If the space vehicle and Up
17. Lower Ring of the Lightband was 30 C Lightband Thermal Transient Test Results 900 W T1Motor A E T Upper Ring T3 Lower Ring Ti c e T4 Lower Ring un I e o im al ii i a m c 100 Time s Figure 7 3 Thermal transient test results 23 Source Appendix A of Spacecraft Thermal Control Handbook Volume 1 Edited by Gilmore 24 Source PSC Document 2000715A 10 July 2014 www planetarysys com Page 54 of 97 2000785E User s Manual for Mark II Lightband Planetary Systems Corporation 8 Lightband Shock The Lightband generates shock during the separation event Many PSC shock tests were excerpted to generate the following data on the shock of separation events and transmissibility The shock response spectra SRS are calculated with 1 3 octave and 596 damping Shock testing has consistently produced the determination that the Lightband substantially attenuates shock in a typical flight stack 8 1 Maximum Shock from the Lightband To characterize shock produced by the Lightband accelerometers are fastened to flanges of structures adjoining the Upper and Lower Rings The accelerometers measure the expected shock at the simulated space and launch vehicle interfaces Generally shock is less at the Upper Ring interface EN D tz 2 4 2 oO i 0 06 0 08 Time s Time History Shock from Lightband 31 LighRed DarkRed 845 1 00E 06
18. Qualification Test Tested strength limits of a 15 inch diameter Lightband are shown in Table 16 6 The Lightband operated nominally after completion of test Load Application Functional test following all load cases Operation 2 Voltage V Load Case 1 Load Case 2 0o 900 _ 0 0 0 35589 o Max Allowable Pre test Analysis Line Max Yip or Zip Load Case Load Ib leaf Line Load Axial Ib leaf Shear 1 1 875 1 875 5 5 7 5 Max Actual Ib leaf Magn 000 003 Margin Allowable Max Actual 1 Table 16 6 Previously tested strength limits of MLB15 000 10 July 2014 www planetarysys com Page 81 of 97 2000785E User s Manual for Mark II Lightband Planetary Systems Corporation 16 4 Shock Qualification Test Tested maximum applied shock levels on a 15 inch diameter Lightband are shown in Table 16 7 and Figure 16 3 The Lightband operated nominally after completion of test Applied Shock g Lower Upper me 1 me m 11943 3 000 3000 5986 11943 3 001 3000 5986 16870 10 000 3000 5986 16870 Table 16 7 Previously tested applied shock levels for MLB15 000 AS NK _ TIN TN T e EN EM M es EM pM LE p ooo __ PENNE es NEN 7 ower Tolerance E 3 9 p
19. Time Figure 15 5 Nominal simulated thermal profile during test 10 July 2014 www planetarysys com Page 72 of 97 2000785E User s Manual for Mark Il Lightband Planetary Systems Corporation 15 1 3 Separation Reliability Test Location PSC Objective Verify separation velocity time to separate time to initiate rotation rates and repeatability Test Description During this test the test item will be repeatedly separated on a 5 degree of freedom test fixture For each separation the separation velocity and rotation rates of the separating half of the fixture will be measured along with the standard operation data such as motor current draw and time to initiate If necessary the configuration and quantity of Separation Springs may be modified to meet separation velocity and rotation rate requirements Upon completion of 10 consecutive separations where all requirements are met the test item will formally inspected to verify that it still operates nominally The separation reliability test is usually tailored to each mission because the separation velocity and rotation rates may be unique In the rare case that the CM is not on the Lightband PSC can test by shifting the Lightband WRT the center of the spherical air bearing Thus the CM offset can be nullified by relocating the sum of the spring s action to the CM This operation is not trivial and adds substantially to this test effort Customers should be sure such a test is warranted bef
20. a single Motor can provide Beneficially if the Lightband can t be stowed this indicates a fault in the Motor Bracket Assembly If it can be stowed this indicates the Motor Bracket Assembly is functional Maximum reliability of the Lightband can be attained by minimizing the power into the Lightband and the number of cycles Specifically avoid unnecessary stow and deploy operations and minimize specified voltage levels Higher voltages will put more power into the mechanism More power leads to higher current which leads to higher torque which leads to higher stresses in the Motor Bracket Assembly 13 Source PSC Document 4000697B 10 July 2014 www planetarysys com Page 42 of 97 2000785E User s Manual for Mark II Lightband Planetary Systems Corporation 6 3 Wiring Harness Design In the beginning of programs engineers and program managers often underestimate the cost weight and size of wiring harnesses This is due in part to the difficulty of modeling a harness using CAD software Harnesses sometimes cost and weigh more than the Lightband If the net shape of the harness is not predetermined it may not fit and will require extensive re work As such it is absolutely essential to complete a detailed CAD model of the wiring harness PSC does not supply harnesses from the Lightband or through the Lightband Figure 6 3 A fully featured 3 0 Ib harness on a 5 2 Ib separation system Users should anticipate the process of attaching the har
21. because separation systems are designed to be more flexible than adjoining structures It may be tempting to design flexible features to attenuate stress exhibited in the warped structures that are joined However this can lead to an unacceptably low stiffness and first mode frequency of the entire system To achieve both a low stress and high stiffness system flatness of the adjoining structures must be controlled Isolation systems like Moog CSA Engineering s SoftRide intentionally add flexibility to joints to attenuate response Furthermore isolation systems offer an additional benefit in the substantial relaxation of adjoining structure flatness requirements Finite element models FEMs nominally assume perfect flatness of adjoining structures Therefore FEMs can obscure this potentially significant reduction in structural margin Figure 5 24 FEM simulates a clamp band separation system via radially inward preload from band tension Warping can result URES in 0 014 0 013 0 012 0 011 0 010 0 008 0 007 0 006 0 005 0 004 0 002 0 001 0 000 Figure 5 25 A deflection of 0 004 inches at the interface to adjoining structures is created by preload 10 July 2014 www planetarysys com Page 30 of 97 2000785E User s Manual for Mark II Lightband Planetary Systems Corporation Lightbands and Clamp Bands embody the perverse nature of mechanical assembly not only do they warp in proportion to preload but a warp applied to them
22. best chance for successful Lightband Flexure flex enough during operations operation Lightband integration and operation Difficult to meet flatness requirements via Less difficult to meet flatness requirements Relative Cost to Relative Cost to Ensure Manufactured Flatness High Medium N Y MENGE UD opo uem us A C epe I MM oe O aha O C I p 0 6 Side View 4 x c zd a Fry de E ES UA re TER wore 1 fe rmi mE CE Isometric View Table 5 5 Comparison of Lightband adjoining structures 10 July 2014 www planetarysys com Page 25 of 97 2000785E User s Manual for Mark II Lightband Planetary Systems Corporation 5 10 Fasteners to Adjoining Structures PSC does not provide fasteners to adjoining structures However PSC uses MS16996 24 fasteners torqued to 100 15 0 in lb in acceptance and qualification tests Exceptions to this torque specification have been made during proof tests in order to prevent bolted joint slipping Fasteners have never displayed degradation during any test at specified bolt preloads 14 inch socket head cap screws with small pattern washers are recommended when fastening from the Upper or Lower Ring to adjoining structures The through holes in the Upper and Lower Rings are nominally 0 280 inches in diameter This allows for 0 030 inches of gap between a inch fastener and the through hole This is benef
23. can affect their preload Critically as many mechanisms engineers have observed in test the structural performance strength and stiffness is highly correlated to preload PSC engineers often observe changes in internal strain as structures are joined to the Lightband A 2096 change in preload as the separation system is fastened to an adjoining structure has been observed Easily fabricated structures adjoining separation systems may be expensive to make flat Alternatively structures that may be expensive to fabricate can be easy to make flat For example a thrust cone that interfaces the final stage engine to the launch vehicle can be easily made by riveting machined rings to conical sheets The riveting process can stress the thrust cone This may manifest itself as warping a lack of flatness when the riveted structure is removed from its much more rigid tooling To attain flatness requirements the riveted structure must be machined or shimmed at additional cost As a more expensive option the thrust cone could be directly machined from a conical forging ensuring flatness requirements are met Engineers should consider the fact that all manufacturing and joining processes riveting for assembly fastening to adjoining structures curing of composites increase strain energy and thus will warp structures 5 13 Damping Ratio Damping ratio may be used to calculate the response of a structure attached to the Lightband A greater damping ratio r
24. diameter This assures separation and nominal rotation rates Please provide PSC with the required relative velocity and the mass of the adjoining vehicles before Separation Reliability testing to ensure accurate results See Section 5 21 for spring force values Determine if a roll rate is required Sometimes customers desire a rotation rate of the space vehicle s thrust axis following separation PSC can produce roll rates up to about 10 degrees per second using a proprietary Roll Bracket Assembly During separation the assembly s rollers contact each other causing a roll rate about the axis The slots in the bracket allow engineers to vary the interference of the rollers and thus vary the roll rate during separation reliability testing The Roll Bracket Assembly mounts on the same features as the Separation Connector and Switch and thus the sum of Connectors Switches and Roll Brackets must be less than or equal to the allowable quantity given in Table 5 1 This is not a standard accessory offered with every Lightband Figure 9 3 Roll Bracket Assembly rendering and installed a Lightband Determine the quantity of Separation Switches and their configuration As with Separation Connectors fewer Switches allow for a simpler harness If more than two Separation Switches are required an additional cost is typically incurred Determine the number of Separation Connectors and their location The greater the quantity of Separation C
25. el U t Nominal Frequency Hz Figure 16 3 Previously tested applied shock levels for MLB15 000 10 July 2014 www planetarysys com Page 82 of 97 2000785E User s Manual for Mark II Lightband Planetary Systems Corporation 17 Lightband Inspection After each acceptance test the Lightband goes through a standardized inspection procedure defined in PSC Document 2001066 Mk Il MLB Inspection Report The purpose of the inspection is to characterize the condition of the Lightband in a consistent and quantifiable manner Each subcomponent of the Lightband is examined and measured where applicable The actions of this process are performed by the Test Director and independently verified by another PSC Engineer who acts as quality assurance Inspections can be performed at any time not just at the conclusion of a test This inspection shall be deemed successful if all of the responses shown in Table 17 1 are yes PSC reserves the right to pass a test item if two PSC engineers and either the Chief Engineer or President determine a inspection point is non detrimental to the future operation of the Lightband For example a piece 0 05 x 0 05 inch of staking comes off during test but the remaining staking is clearly in place around a fastener head PSC also reserves the right to fail a test item even if the answers are all yes given the same criteria QA Date amp Tech Item Description Date amp I
26. esami n eem EE ad a ee dus ue imi m 7 m ITE uw ar i im y b mj E manum red Figure 6 6 Separation Switch as described in PSC Document 2002204 Separation Switch Data Sheet PSC does not mark the solder eyes on the Switch so a multimeter should be used to verify which circuit s to solder to during installation During a past vibration test performed by PSC intermittencies were detected on circuits through the Switches at random vibration levels of 17 Gms During this test the vibration spectrum was biased towards high frequency In the case where users anticipate operating in an extreme environment de bounce circuitry in the electrical path may be useful 10 July 2014 www planetarysys com Page 45 of 97 2000785E User s Manual for Mark II Lightband Planetary Systems Corporation 6 6 Voltage Current and Duration of Lightband Operations The following figures and tables define the nominal electrical properties of the three Lightband operations stow set for flight and deploy The quantity of powered motors temperature and commanded voltage affects the time to initiate the Lightband Figure 6 11 and Figure 6 12 show initiation voltage as a function of time to initiate for both motors and a single motor actuation at various temperatures TE TEE Stow limit switches cut power Pa Voltage rapidly decays Current
27. loading on the spacecraft SoftRide is a patented product of Moog CSA Engineering www csaengineering com It has been flown successfully at least 19 times including 6 flights with Lightbands on the XSS 11 TacSat 2 3 4 IBEX FalconSat 3 and GRAIL missions ore neat _ Spacecraft Table 5 8 Valuable payloads are isolated from detrimental external loading using spring damper isolation systems SoftRide Systems have several benefits when used in conjunction with the Lightband 1 Substantially reduce flight loads into the payload such as engine transients random vibration and shock 2 Substantially reduce risk by isolating the payload from unanticipated launch load events 3 Substantially increase damping SoftRide damping ratio range is 396 to 25 depending on the needs of the mission 4 Reduce stiffness requirements of the space vehicle because there Is less value to a very stiff bus if it is sitting on a very flexible isolation system 5 Reduce flatness requirements of adjoining vehicles because the isolation system is flexible 6 Ease integration of the Lightband by eliminating the need to stow the Lightband to join the satellite to the launch vehicle With the isolation system attached to the already stowed Lightband integration can occur by simply fastening the launch vehicle to the isolation system Figure 5 28 A rendering of CSA s SoftRide OmniFlex which isolates the satellite from the launch ve
28. stops Second peak current 2 Voltage Vdc Data sampled at 1 000 S sec DAL Power On Motors powered 3 Voltage Mtr A Voltage Mtr B Current Mtr A Current Mtr B Recoil voltage Time sec Description First peak currente Second peak current Motors powered duration Table 6 1 Nominal stow electrical properties 14 Source PSC Documents 2002305 2001044 and 2000715 15 Source PSC Document 2000781E 16 First peak current equals V R with T in degrees Celsius When turned on the current rises to V R for no more than 0 02 seconds The winding resistance R of the Motors is 10 3 O However R varies with temperature in accordance with Equation 7 This equation comes from manufacturer s technical specifications R 10 3 1 0 0039 T 25 7 10 July 2014 www planetarysys com Page 46 of 97 2000785E User s Manual for Mark II Lightband Planetary Systems Corporation Stow limit switch s initially cut power Voltage rapidly decays First peak current 1 Current rise detected on BOTH channels until one or both switches cut power 3 System will then chatter or stall depending on switch synchronization Free running current 2 Power on Time to initially cut power 4 Voltage Mtr B Current Mtr Data sampled at 1 000 S sec Voltage Mtr A
29. tested in an environment that is visibly clean The thermal vacuum acceptance test tends to boil off volatile contaminants and expose the presence of contaminants by not allowing the chamber to reach low pressure states 106 5 Torr As such the thermal vacuum test tends to clean the Lightband of volatile materials or expose the presence of unacceptable contamination The Lightbands are covered when not in use at PSC The shipping methods section shows the contamination control methods used in shipping Figure 13 1 Viton bumpers can be a small debris source The Viton bumpers can shed 0 005 inch diameter debris if the Lightband is stowed and deployed beyond its useable life When the Lightband is separated and not attached to other structures it is in its most flexible and fragile state When the Motor Assembly is exposed to accidental loading the mechanical junctions may loosen This could lead to cracking of Motor Assembly components The Separation Connectors can collect debris when the Lightband is in a deployed state This can lead to inadvertent intermittencies PSC recommends that the exposed Separation Connector pins be covered when in the deployed state for extended durations Lubricant Braycote 601 is applied in several locations and should not be removed by cleaning processes Lubricant is located in the Motor Bracket Assembly the Retaining Ring Assembly the Leaf Assemblies and in the accepting groove of the Upper Ring 10 J
30. the results of the test The outcome of the meeting is to deem the test a success or failure At a minimum two PSC engineers and either the Chief Engineer or President must attend TML Total mass loss WRT With respect to 10 July 2014 www planetarysys com Page 96 of 97 2000785E User s Manual for Mark II Lightband Planetary Systems Corporation 29 Acknowledgements PSC would like to thank Mike Froelich of Ball Aerospace and Greg Rahal of Orbital Sciences Corporation for their many constructive suggestions and patience with several of the anomalies PSC encountered as the Lightband attained its present maturity 10 July 2014 www planetarysys com Page 97 of 97
31. 11 lege Il Class 1 4000529 Al SST Delrin Neodymium N Y Blakanoize Spherical Plain Bearing Proprietary Carbon Chromium Steel __ Mason _ 2 2 Al 7075 T7351 AMS QQ A Chem Conv color gold per Mil DTL Link Retaining Ring Proprietary PH 15 7 Mo Stainless Steel M EN 21 GeaCoe 4000440 300 Series Stainless Steel 300 Series Stainless Steel Stainless Steel ON oN 2 2 Al Aly 7075 T7351 AMS QQ Chem Conv color gold per Mil p E incid A 250 12 EET Pen 5541 CI 3 Al Aly 7075 T7351 per AMS QQ Chem Conv color gold per Mil DTL POENA PAE aoe A 250 12 LU LIA T melt 5541 CI 3 H3 Limit Switches Proprietary Valox 420 Phenolic SST Silver LM Link Plug 4000443 Viton Rubber ND Assorted Shins Sess Steel _ HEME Fm Om ees esenee 31 Ring Roller 4000398 800 Stainless amp Petin 6061 T6 per Dein ee Anodize per Mil A 8625 Type eT 225 8 Ill RS 1 Separation Spring 4000307 300 ag Sane Se Stainless amp Delrin PSC Al Aly 6061 T6 per AMS QQ nf ON n Nickel per AMS C Separation Switch 4000383 Al Aly Stainless Steel Gold pon foe fon Chem Conv Ea per MIRRE Roller Spring Proprietary 300 Series Stainless Steel oh OM I TI S S Proprietary Roller Spring Base 4000426 300 Series Stainless Steel NM Passivat
32. 3 5 2 HOW THE LIGHTBAND WORKS eere ea ee brace iy eee eL ec eee Re ye ooo ee UE veu ve OR neon d iv cab a nive Ev cu va o pe ru div REEL aN 15 33 HOW THE MOTOR BRACKET ASSEMBLY WORKS eor ero UE dae ses eat 17 SPA MENS e ENTE 19 5 5 GENERAL CAPABILITIES AND ISIMERSIONS LL uL S Ene eu E DEAL E Ens LR DL E UE 21 p6 ROLERANGE DIMENSION co Rt RN 22 XO UN Sc get aa d Rem n 22 5 9 GOMPLIANCE sees tl Ba fed oa cate 22 5 9 DISCUSSION OF FEATURES ON ADJOINING STRUCTURES cceccececececcecececcceucececucucueauaeserscauauaesersuauauaeserseaeuaenetsuataveeauaesersvetauaeaenscetenaenes 23 5 10 PASTENERS TO ZABIOINING OTR UCTUBESIS S circle eM ieri P S Lin ea uta ME ln P DD DE EDDA LL DIM LINE 26 5 11 E ONERE RU TRAE UE IE SEEE EEI KEVI IE CRIE EENE EUR 27 5 12 e iaceret iie N ecu er E e E E 30 5 13 EJAMPING Nu EEE rt iP Eco ee I 31 5 14 SOFTRIDE AND TIO ERI 32 5 15 WES TH 33 5 16 DEPLOY AND STOW CYCLE H c
33. 6 1 423 9 696 1 1 637 1 5 622 2 2 648 4 2 985 1 1 720 6 866 3 lom in 1 8 lyy upper assembled 77 upper assembled 42 1 855 5 bo lower assembled 228 9 2 129 5 lower assembled 96 8 960 3 7 lower assembled 134 7 1 174 7 X axis lb 26 320 26 320 30 080 33 840 45 120 56 400 oa Yip or Ze axis Ib 5 418 5 418 6 192 6 966 9 288 11 610 4 Moment about Y or Zs in lb 120 085 130 600 174 840 203 040 356 448 547 221 Max sum of Separation Connectors Switches C MA and Roll Brackets 2 Max number of ightband Comp os 12 w 16 e 2 2 5 5 6 7 6 axis stiffness 25 Ib in 6 1 80 06 2 64 06 2 93 06 3 38E 06 4 11E 06 4 47 06 Bending stiffness about Yig or Zg 25 1 40E 07 4 43 07 6 02E 07 9 25 07 1 67 08 2 14 08 3 44 08 3 79E 08 8 65E 08 1 60E 09 in Ib rad 6 Required flatness of adjoining structure if xxxx structure is flexible in 7 0 0028 0 0042 0 0046 0 0053 0 0065 0 0071 0 0083 0 0085 0 0112 0 0138 Required flatness of adjoining structure if LI xx structure is stiff in 7 0 0021 0 0031 0 0035 0 0040 0 0049 0 0053 0 0062 0 0064 0 0084 0 0103 1 Does not include separation connectors springs or switches 2 For example on an MLB 15 there may be 4 separation switches and 2 separation connectors 4 2 6 3 Though there is room for more using more than 24 springs will sub
34. 785E User s Manual for Mark II Lightband Planetary Systems Corporation 15 2 2 Shock Test Location PSC Objective Measure the shock produced by the test item during separation and prove that the test item can operate nominally after being exposed to required shock profiles Test Description During this test the shock produced by the test item during separation will be measured Then the test item will be exposed to the required shock profiles Upon completion of shock exposure the test item will be separated and then formally inspected to verify that it still operates nominally Standard Levels Shock applied to the Lightband is shown in Table 15 4 and Figure 15 10 These values are derived from MIL STD 1540 E Test Requirements for Launch Upper Stage and Space Vehicles SMC TR 06 1 1 Number of separations One 1 following all load cases Criterion for performing test The unit is expected to be exposed to a shock spectrum not previously experienced by a Lightband PSC will determine whether this criterion is true during the contract negotiations process 1 Aceletin g ZH O __ 00 580 100 JJ MERE 60 bO C 9 U t Frequency Hz Figure 15 10 Nominal shock profile applied to Lightband 10 July 2014 www planetarysys com Page 77 of 97 2000785E User s Manual for Mark II Lightband Planetary Systems Corporat
35. B15 000 shown 10 July 2014 www planetarysys com Page 71 of 97 2000785E User s Manual for Mark II Lightband Planetary Systems Corporation 15 1 2 Thermal Vacuum Test Location PSC Objective Verify time to separate at temperature and pressure extremes Test Description During this test the test item will be thermally cycled while inside a chamber that creates a partial vacuum as a simulation of in flight conditions At various points throughout the cycling the Lightband will be initiated from the stowed state Upon completion of cycling in partial vacuum the test item will be formally inspected to verify that it still operates nominally A dwell in excess of 10 minutes is unnecessary because the Lightband is relatively conductive unlike for example an avionics box which may possess many structures that are poorly coupled to the thermal sink Standard Levels 70 C bake out for 60 minutes then 24 0 to 456 0 C 4 cycles 10 Torr 10 minute dwells Number of separations One separation after the 1 cycle at low temperature and another after the 4 cycle at high temperature PSC Test Thermal Vacuum Rack Chamber shown without lid Figure 15 4 4X MLB11 732 inside the PSC Thermal Vacuum Chamber Thermal Cycle Profile Bakeout 2nd Separation 7 Test Complete gp O Oo 5 dud o gt p Stow at Ambient Test Begins 1st Separation Cycle No 1
36. BS Progress Reporting Testing Schedule Vibration 1 Thermal Vacuum 2 amp Separation Reliability 15 Legend X Typical number of separation tests End ltem Data Package EIDP As run test plans production lag RWM and certification PSC PSC quality engineer Lightband Training Teach customers to use Lightband Customer representative s Figure 14 1 PSC s standard manufacturing process or z T Figure 14 2 Lightband assembly at PSC 10 July 2014 www planetarysys com Page 67 of 97 2000785E User s Manual for Mark II Lightband Planetary Systems Corporation Figure 14 3 PSC s flight hardware assembly clean room 10 July 2014 www planetarysys com Page 68 of 97 2000785E User s Manual for Mark II Lightband Planetary Systems Corporation 15 Acceptance Testing of Lightbands PSC completes three standard acceptance tests Vibration Thermal Vacuum and Separation Reliability on flight Lightbands prior to delivery This is part of PSC s quality assurance plan EDU Lightbands are only put through several bench top separation tests Just like during assembly testing is performed by a team of PSC engineers Two engineers sign off on individual steps in testing procedures one acts as the test director the other as quality assurance and three engineers execute a Test Complete Review TCR as the final step in the completion of the test procedures The Lightband is tested as a unit with respect to t
37. Current Mtr B I 0 8 Time sec Figure 6 8 Nominal set for flight voltage and current profiles at P 1 0 Atm and 23 Description Table 6 2 Nominal set for flight electrical sonrisa 17 Source PSC Document 2000781E 10 July 2014 www planetarysys com Page 47 of 97 2000785E User s Manual for Mark II Lightband Planetary Systems Corporation First peak current 1 Voltage Mtr A Voltage Mtr B Current Mtr A Current Mtr B Deploy limit switches cut power Current stops Voltage decays N Data sampled at 1 000 S sec Power on Motors spin down 3 Motors powered 0 10 Time sec Description First peak current Motor powered duration 3 Motor spin down duration Table 6 3 Nominal deploy electrical properties If the set for flight operation is skipped the Lightband will require about 0 65 seconds to initiate Further detail is available in PSC Document 2000901 Vibration Qualification Test of Motor Bracket Assembly Do not skip the set for flight operation As the preceding figures show the Motors are not only the means to initiate separation but outstanding transducers that indicate the state of the Lightband Power voltage multiplied by current energy integral of power and torque torque constant multiplied by current can easily be calculated via motor response data When necessary this gives engineers a thorough understanding of Lightband performance PSC uses the ci
38. E User s Manual for Mark II Lightband Planetary Systems Corporation 12 Determine if an Engineering Development Unit EDU is needed EDU Lightbands differ from flight Lightbands in that EDUs receive only a bench top separation test rather than a full slate of environmental testing prior to shipment Customers often use EDUs for fit checks and ground testing Because they do not receive acceptance testing EDUs shall not be used for flight As such EDUs are indelibly marked NOT FOR FLIGHT 13 Specify the Launch Vehicle PSC may have insights into unpublished LV limitations or benefits 14 Determine the acceptance testing required PSC performs three standard tests vibration thermal vacuum and separation reliability to the levels defined in Section 15 of this document Optional testing includes strength and shock tests If further testing is required please contact PSC 15 Specify the Lightband Use the following convention to specty the Lightband you need Diameter Spring Qty Switch Qty Connector Pair Tool EDU MB XXXXX X X Table 9 1 Lighiband For example MLB15 000 8 2 1 0 8 FLT specifies a 15 inch diameter Lightband with 8 Separation Springs 2 Separation Switches 1 Separation Connector 0 Roll Brackets and 8 Lightband Compression Tool pairs that will receive flight acceptance testing and be used for a space flight Using this convention will ensure that there are no issues communicating ex
39. II Lightband o CM n Ls COS orf Lm LU B MAP LI 5 o 3 o im gt o a m J D x lt T mn o E o 2 o E o te t c 9 Q o T I lt lt N A 5 Oo LL Figure 2 3 Four and one Lightbands used to separate five spacecraft on STP S 26 in November 2010 28 S1 5EO7 amp www planetarysys com Page 7 of 97 10 July 2014 2000785E User s Manual for Mark II Lightband Planetary Systems Corporation 19 8 inch 23 25 inch Mk I Lightband 2 x Figure 2 6 Three Lightbands 38 8 31 6 and 15 0 inch diameter are used on the IBEX Program 10 July 2014 www planetarysys com Page 8 of 97 2000785E User s Manual for Mark II Lightband Planetary Systems Corporation Figure fae Tia 2 9 Lightbands on ESPA STP 1 on an Atlas V 10 July 2014 www planetarysys com Page 9 of 97 2000785E User s Manual for Mark II Lightband Planetary Systems Corporation 4 E ES fd S 4 f M 4 Mi y oo vi ANN SR NCAR ES N SN Figure 2 11 The PSC Team 1 Source http www nasa gov sites default files ladee_encapsulation jpg 10 July 2014 www planetarysys com Page 10 of 97
40. Leaves to bear upon the Retaining Ring After the motors have been initiated the Retaining Ring no longer reacts the inward Leaf Retaining Cord force The Spring Plungers fastened to the Upper Ring then cause the Leaves to disengage from the Upper Ring after the Sliding Tube has snapped inward See Figure 5 6 and Figure 5 T p M cnm CA P Conn D m SS 6 c Mc ER a A M d Aie ee 0 gt pH 2 Lo x 5 SS E Nh iin nimi lt C ___ 1 trou d Te Leaf Retaining Cord et Figure 5 7 The Leaf Retaining Cord and the spring plungers shown in the stowed state Upper Ring hidden for clarity Figure 5 8 illustrates the Leaves disengaging due to the force from the Spring Plungers allowing the Separation Springs to push the rings apart Figure 5 8 The Lightband shown deploying or separating 10 July 2014 www planetarysys com Page 16 of 97 2000785E User s Manual for Mark II Lightband Planetary Systems Corporation 5 3 How the Motor Bracket Assembly Works The Motor Bracket Assembly MBA is the actuator of the Lightband In the MB two DC brush Motors connect to bevel gears The stainless steel bevel gears connect to a brass
41. M M GEMENS UEM 1 3 deploy 01 6 A amp B 28 0 28 241 28 161 2 665 2 430 0 055 0 658 1 916 0 597 1 277 4 88 0 458 1 503 1422 1397 Mean Minimum Maximum Standard Deviation 0 010 0 086 0 216 0 044 0 002 0 01 0001 0002 06 Allowable Maximum Allowable Minimum Separating Half Mass Notes lb 1 About CM center of spherical bearing and aligned with Lightband coordinate system kg 2 For acceptance trials only 3 Assumes the following masses kg FS 3000 5 47 4 Time from power on until either deploy limit switch initially opens Figure 15 8 Nominal test results from separation reliability test conducted on an MLB15 000 10 July 2014 www planetarysys com Page 75 of 97 2000785E User s Manual for Mark II Lightband Planetary Systems Corporation 15 2 Optional Acceptance Tests The following acceptance tests are not standard and are not usually performed for each flight Lightband produced Criteria that determine the need for these tests are stated herein 15 2 1 Strength Test Location PSC Objective Verify strength of the Lightband Test Description During this test the test item will be exposed to quasi static loading that is intended to simulate in flight acceleration forces in the stowed configuration Each combination of loads is known as a load case Upon completion of all load cases the test item will be separated and then formally in
42. NSTS 08307 document outlines a thorough bolted joint analysis Stiffness is affected by bolted joints Generally a greater pre load leads to greater stiffness Ideally the Lightband should be fastened to adjoining structures when the Lightband is separated This allows easy access to the fasteners with tools When the Lightband Rings are mated together barely sufficient access to fasteners is available from the inside of the Lightband It is essentially impossible to fasten a mated Lightband to adjoining structures if access to fasteners is only available from the outside of the Lightband 5 See PSC Documents 2002319A and 2002512 6 See PSC Document 2000781 10 July 2014 www planetarysys com Page 26 of 97 2000785E User s Manual for Mark II Lightband Planetary Systems Corporation 5 11 Line Load Limits Line loading in the axis arises from loads in the direction and moments about the or 4 axis Generally the moments about Ysg and Zig generate higher line loading than axial loads In other words lateral load cases are the limiting factor in strength margin axial force d di Maximum Axial Line Load P K force bolt Maximum Shear Line Load Q force bolt Figure 5 20 Line loading forces Force per Bot Direction Yield Limit Ib bolt Ultimate Limit Ib bolt 2256 0 Axial 1880 0 2256 0 od Yin or Zip Shear 774 0 928 8 Table 5 6 Line load limits In
43. PLANETARY 2303 Kansas Avenue Silver Spring MD 20910 SYSTEMS 301 495 0737 CORPORATION info planetarysys com PSC 2000785E User s Manual for Mark II Lightband NOTE To avoid costly test failures and program delays all users should completely understand this document before procurement and use of the Lightband for any purpose Customers are prohibited from operating the Lightband without reading this manual and completing the Lightband Training Course offered by PSC P E m US Patents 6 227 493 6 343 770 6 390 416 2000785E User s Manual for Mark II Lightband Planetary Systems Corporation Table of Contents 1 Pee VISION PAIS TOP h 5 E AE AE EE NE E E NE EEE E E ESE SEEE 4 2 INTRODUCTION wesc ec eae tees cial Seen ee 6 3 WHY CHOOSE LIGHTBAND 222 nnnm 11 4 LIGHTBAND FLIGHT HISTORY MR RErsE 12 5 MECHANICAL 13 5 1 LIGH DBANDIDESCRIPTION RETE RETIRER 1
44. Table 5 6 the Peq and Q values are conservative as no yield or cracking has ever been detected on a Lightband after test when the line load was below prescribed yield limits Ultimate limit in the next column is determined by multiplying yield limit by the ratio of ultimate to yield stress for the materials of the Upper Ring 7075 T7 Lower Ring 7075 T7 and Leaf Assemblies Al Aly 6061 T6 The minimum ratio 1 2 is used as a conservative assumption Each Leaf corresponds to through holes for fastening to the adjoining structures The through holes are sized for 1 4 inch socket head cap screws PSC analysis and tests have shown that the as designed fastener hole size and spacing is optimum for Lightband operation On several occasions customers have opted for smaller fasteners example 10 32 As long as the strength of the bolted joint exceeds the line 7 Per PSC Document 2002319 Rev A Lightband Loading Capability Proof Test 8 Per PSC Document 2002286 Rev D MLB15 000 24 Analysis 10 July 2014 www planetarysys com Page 27 of 97 2000785E User s Manual for Mark II Lightband Planetary Systems Corporation load there should be no issue with a smaller fastener All testing at PSC is performed with 14 inch fasteners because PSC test cells have 1 4 28 accepting threads Axial line loading arises from axial and lateral Yig or Zig loading whereas shear line loading arises from only lateral Yig or Zig loading
45. Test ssssseseesee I I rR nem rRmRR metere tremetremremremerte re re re ii iier ve ra sa s ge sa ri ii reris 80 16 2 THERMAL VACUUM QUALIFICATION TEST nee iva D Re a ves Eee eee Dye EE PE vo totes deve geod ves eee eS Yea ev 81 16 3 m EEUU r 81 16 4 SHOGROBABIEICATION 82 17 LIGHTBAND icis edge eC 83 18 LIGHTBAND 84 19 TESTING AND PROCEDURES PERFORMED BY CUSTOMER cccececeecececececcececececnenececececnenececucnenenenecaeneneneaeaeaeceenensceaeeueneneneaess 85 19 1 DESIGNING THE WIRING HARNESS 22 953 rods aa Sonet reo Emo ex o Erant ips coo deem Eis esa odes aes aoo Pod eno na db o durs 85 20 GROUND SUPPORT EQUIPMENT GSE citu ona saa ake cath axe Euge eu aaa iA aV EE vehe e Claes eso Even Dra Gun UD cun dae caede 86 21 STANDARD LIGHTBAND DELIVERY
46. actly what type of Lightband is needed 16 Contact PSC Contact PSC by phone or email info planetarysystemscorp com to finalize the selection and purchase of a Lightband 10 July 2014 www planetarysys com Page 61 of 97 2000785E User s Manual for Mark II Lightband Planetary Systems Corporation 10 Operating the Lightband All Lightband users are required to complete a training course conducted by PSC engineers It is the customer s responsibility to ensure that they have been trained before operating the Lightband This training is included in the cost and generally performed at PSC s facility in Silver Spring Maryland Without this training the probability of user induced failure will be high See Section 23 The latest revision of PSC Document 2000781 MkII MLB Operating Procedure details the steps to stow set for flight and deploy the Lightband CAUTION Operating the Lightband before receiving training from PSC will void the Lightband s warranty 10 1 Access to Fasteners When the Lightband is separated the fasteners to the adjoining structures are readily accessible When the Lightband is stowed access to fasteners is limited but possible if there is access form the inside such as in ESPA Hex drivers Allen keys need to be shortened Access from the inside is very valuable when removing a stowed Lightband from an adjoining structure 10 2 Vertical and Horizontal Integration to Adjoining Vehicles Without Isolation System With
47. acuum The Lightband motors are DC brush motors The brushes are made of a precious metal and not graphite graphite should not be used in a vacuum because its performance degrades rapidly without water vapor Extensive thermal vacuum testing of these motors in Lightbands shows the motors are not susceptible to failure when used in the Lightband as a separation system The most extreme thermal environment for a was STS 116 Dec 9 through 22 2006 Three Lightbands were used on the CAPE ICU I mission ICU separated from the Shuttle on the 13th day of the mission By then the 3 Lightbands had been exposed to approximately 250 25 to 70 C thermal cycles The temperature at separation was estimated to be 40 On STS 127 July 2009 CAPE ICU II performed same mission was with an additional 3 successful separations Generally the thermal environment of unmanned missions is more benign than shuttle missions because the separation event on unmanned missions usually occurs within minutes of reaching orbit and because high value spacecraft and the final stages of their launch vehicles go to substantial lengths to avoid temperature extremes All flight Lightbands are tested in a thermal vacuum environment at PSC The standard thermal vacuum test is shown in Section 15 1 2 7 2 Survival and Operating limits The survival limit is 68 to 145 The operating limit is 54 to 128 Ideal operating t
48. amp deploy 60 times it must be inspected by PSC and considered for refurbishment The typical refurbishment process is as follows 1 2 3 The Lightband is shipped back to PSC Provenance of the Lightband is established What handling operation testing occurred while outside PSC Analysis of handling and testing is performed to establish potential risks and problem areas For instance what line loading was experienced in test The Lightband is inspected based on Step 3 results This could be as simple as a visual examination or a complete tear down and assessment Only known non destructive inspection techniques like dye penetrant analysis are performed A refurbishment plan for the unit based on Step 4 results is created Examples range from simply re greasing the bevel gears to replacing all components in the load path The refurbishment plan is executed An environmental testing plan for the refurbished unit is determined This could be all or a selection of the acceptance tests defined in Section 15 of this document The environmental testing plan is executed The Lightband is shipped back to the customer PSC engineers use PSC Document 2002653 Refurbishment Procedure to document actions during the refurbishment process 10 July 2014 www planetarysys com Page 84 of 97 2000785E User s Manual for Mark Il Lightband Planetary Systems Corporation 19 Testing and Procedures Performed by Customer Customers often complete some of t
49. ams Records each motor s Rack current and voltage at 5 000 samples second Calculates power energy and duration Weighs 130 Ib When blind mating is required these pins add control to the mating process Note the Separation Springs already provide this function Alignment pins Lightband Overcome the Separation Spring force Compression Tool when the payload is integrated This PSC Part can substantially improve the available Number 4000637 payload integration options Lightband Stiffness Simulator Emulates the stiffness of a Lightband Crane Compliance Allows for axial compliance when Sling PSC Part mating the Upper and Lower Rings of Number 2002215 the Lightband On the MLB 15 000 24 PSC has used Reduced head 174 28 socket head cap screws with the dande head diameter reduced to 0 340 in NO This eliminates the interference fit described PSC Document 2000781 Table 20 1 Ground support equipment 10 July 2014 www planetarysys com Page 87 of 97 2000785E User s Manual for Mark Il Lightband Planetary Systems Corporation 21 Standard Lightband Delivery Schedule Machining nS Machining Inspection and assembly Test Readiness Review TRR Z To T T M Vibration Testing o o ooo o o o o Lo Thermal Vacuum Testing To O Separation Reliability Testing To o J jJ O Se RENNES Table 21 1 Typical sch
50. and M AV n is the efficiency kinetic energy after separation stored strain energy before separation E is the stored potential energy of a Separation Spring that is converted to kinetic energy manifested as v The efficiency term n accounts for the losses in the Lightband during separation Testing at PSC has shown n 0 90 0 03 The stored potential energy of a Separation Spring term is a constant for PSC produced Springs Previous testing has shown that E 1 02 0 10 J Observe that as v increases the quantity of and mass from Separation Springs increases with the square of the kinetic energy after separation The allowable quantity of Separation Springs varies by Lightband diameter See Table 5 1 The minimum number of Separation Springs should be six 6 regardless of Lightband diameter to assure reliable separation Final Stage Payload Mass M Mass m Figure 5 32 The relative velocity v is created by the Separation Springs S 10 July 2014 www planetarysys com Page 38 of 97 2000785E User s Manual for Mark II Lightband 1 2 E J 1 02 n 0 9 m Kg 181 0 1 0 300 0 v m sec o o eo 0 0 0 20 40 60 80 S Number of Springs Figure 5 33 Spring quantity required increases with the square of velocity Planetary Systems Corporation The location of Separation Springs Connectors and Switches need not be symmetric to minimize rotation rates Sometimes PSC engineers will mod
51. arated approximately 25 times to verify operability These ground tests are part of acceptance or proto qualification test programs conducted by PSC As shown in Table 11 2 the Lightband allows the user to verify operation multiple times before in flight separation Fairing Sep System Pyrotechnic Sep System Motorized Lightband Typical quantity of separations 25 on flight unit Table 11 2 Comparison of separation system separations before launch Alternatively PSC tests development and qualification units to examine reliability limits and inform the allowable limits of Lightbands in ground test and space flight A typical qualification test will result in more than 100 separation tests on a single Lightband These separation tests are part of all environmental tests Because of the reusability of the Lightband and the high production rate it has been inexpensive to amass test data that is several orders of magnitude larger than competing pyrotechnic systems The Lightband was designed to be reusable with the intent of demonstrating reliability Stowing consumes about 20 times more energy than deploying So the act of stowing the Lightband before flight accurately indicates the capacity of the Lightband to deploy and separate on orbit If the Lightband cannot be stowed it indicates one of the motors is inoperable The setting for flight operation completed after the Lightband is stowed is a low power operation completed by both motors If
52. ces Section 5 10 Added discussion of reduced head diameter fasteners Figure 5 26 Updated Figure 5 34 Updated Section 6 3 formerly Deleted because it was superseded by Section 6 10 Figure 6 2 Updated to graphic from 4000697B Section 7 3 Added absorptivity and emissivity ranges for hard anodize Figure 8 5 Added a legend Section 9 Added step 15 and Table 9 1 Section 9 Added comment regarding not for flight marking on EDUs in step 12 Figure 9 1 Updated to reflect current standard tests and number of seps Figure 14 1 Updated to reflect current standard tests and number of seps Figure 14 3 Added Table 15 1 Changed number of TVac separations from 1 to 2 Figure 15 3 Updated with more recent test photo Figure 15 4 Updated with more recent test photo Section 15 1 2 Updated with latest test standards Section 15 1 3 Updated with latest test standards Table 15 3 Updated Figure 15 8 Updated Figure 15 11 Added Section 17 Updated with latest procedure from 2001066B Section 18 Added reference to document 2002653 Section 20 Added reduced head diameter fasteners Section 23 Added Table 24 1 Updated photo of hex standoff Table 24 1 Added row regarding customer unpacking www planetarysys com Page 5 of 97 2000785E User s Manual for Mark II Lightband Planetary Systems Corporation 2 Introduction The Lightband is a space vehicle separation system It is used to separate space vehicles from
53. ch vibration inputs and broke Lightband Leaf then kept testing pm ae er pun Figure 12 2 A Leaf from a Lightband cracked in half during a flawed random vibration test e A customer had PSC engineers fly to Kodiak AK to fix a broken Lightband only to discover the customer was improperly operating a multimeter used to verify Lightband operation customer forgot the Lightband was connected to the power supply during a ground test of the initiation electronics The Lightband deployed and the cantilevered structure separated damaging the Lightband A customer miswired the cable from the launch vehicle to the Lightband resulting in stalling the motors for approximately 60 seconds The most common customer errors arise when they fail to follow stow procedures properly or fail to verify electrical connections These failures are typically discovered soon after receipt by customer and at considerable cost To prevent this failure mode all Lightband users are required to complete the aforementioned Lightband training course provided by PSC at no extra cost and urged to study this manual in detail See Section 23 10 July 2014 www planetarysys com Page 65 of 97 2000785E User s Manual for Mark II Lightband Planetary Systems Corporation 13 Cleanliness amp Handling Users should store and operate the Lightband in a visibly clean environment The Lightband should be covered when not in use The Lightband is assembled and
54. ck vibration and thermal vacuum environments Design features include Prevents incorrect Lightband alignment via a keying feature e Separates in parallel with the Lightband to ensure minimal induced rotation e Canship ahead of the Lightband and allow the harness to be manufactured concurrently by the customer In such a case the harness may be attached to the Lightband whenever convenient for the customer The Connectors can also ship with the Lightband if desired by the customer Occasionally Lightband users desire to employ PSC Separation Connectors as used as electrical loop backs This should be done with caution as the junction can be intermittent due to very high shock and vibration Employing redundancy and de bounce into the circuits has been shown to alleviate this concern Alternatively Separation Switches may be employed instead of loop backs 10 July 2014 www planetarysys com Page 44 of 97 2000785E User s Manual for Mark II Lightband 6 5 Separation Switches Planetary Systems Corporation The Separation Switch is designed by PSC and may be attached to the Upper or the Lower Ring It is used to communicate the separation Data Sheet event to either adjoining vehicle A full description of PSC s Separation Switch can be found in PSC Document 2002204 Separation Switch aS am te 7 mm IB Bua yP i L 3 MN LLL i hl 5 quatem e L
55. common Bevel Gear and that common Bevel Gear connects to the stainless steel Ball Screw The Ball Screw connects to a Ball Nut which bears upon the Stow or Deploy End Plate depending on the Lightband operation The Sliding Tube encloses the Ball Nut and is fastened to the Linear Way which slides on the Rail The Sliding Tube is connected to the Links via spherical bearings which in turn control the motion the Retaining Ring The Motor Bracket constrains the linear motion of the Sliding Tube with elastomeric non out gassing bumpers at the deploy end and with hard stops at the stow end The lubricants Braycote 601 EF and molybdenum disulfide are space qualified and non outgassing The Limit Switches are arranged to cut power when physical limits stow set for flight and deploy are reached All of the set screw junctions in the MB are redundant and bear upon flats or bores All fasteners are staked with Arathane after being torqued The Motors are redundantly fastened to the Motor Bracket and staked to the Motor Supports The motor pinions between the Motor and Planetary Gear are connected to the motor shafts redundantly a weld and a shear pin Except for the spherical bearings there is no sliding friction all of the motion of this assembly is strictly rolling The deploy operation is fully reversible though it takes more energy to stow than deploy the Lightband As a reliability feature the Lightband will not stow if only one Motor is operable I
56. e AMS QQ P 35 Type II psc Roller Spring Slider 4000427 300 Series Stainless Steel lm Passivate per AMS QQ P 35 Type II Leaf Fasteners Proprietary A 286 vales 41 9 Pin Connector HDC9S2000S Bronze Stainless Glass Filled N N positronie Ind Gold Staking Compound Arathane 5753 LV 1 s Per MSFC STD 3029 Z Z z z di HE ii 2 2 2 n Table 5 9 Lightband materials and surface treatments 10 Source PSC Document 2000849A MLB Materials and Surface Finish List 10 July 2014 www planetarysys com Page 34 of 97 2000785E User s Manual for Mark II Lightband 5 19 Part Marking Planetary Systems Corporation Each Lightband is marked with its assembly number serial number and coordinate system on both Upper and Lower Rings PSC does not provide customer specified part marking tagging or bagging 5 20 Subsystem Weights Unit PSC part number Weight Ib Upper Separation 4000107 0 025 Connector Lower Separation 4000106 0 025 Connector Separation Spring 4000307 0 032 Separation Switch main 4000383 0 039 body Separation Switch 4000383 0 006 bracket Roll Bracket Assembly 4000585 0 090 0 010 4000637 each not y per pair The Upper Connector may be placed on either the Upper or the Lower Ring of the Lightband Includes mounting hardware See PSC Document 2001025 See above Includes mounting hardware Includes mounting hardware See PSC D
57. e contact See Figure 5 35 Figure 5 35 Simulated view of several payloads on the same launch vehicle 10 July 2014 www planetarysys com Page 40 of 97 2000785E User s Manual for Mark II Lightband Planetary Systems Corporation 6 Electrical Properties 6 1 Schematics Lightband after deployment Lightband is separated Lightband Upper Ring Typically on Space Vehicle 9 Lightband ready for flight Lightband Upper Ring Typically on Space Vehicle Separation Switch es 6 indicate separation turn on space vehicle Separation Connector s conduct signal and power 1 15 NO NC NC NO L 2 1 spring pin 45 2 EMI Gasket retained by Separation Switch es Boe a have changed state P P Upper EMI Gasket 4 2 Shield NO NC Lower attachment Optional metal Shield M housing attachment Soldereye Notes 1 Brush motors include internal arc suppression Motors connected by common shaft so if only one motor is powered the other creates a voltage across its terminals R winding 7 10 3 Ohm 2 The metal shell conducts tothe Lightband via conductive surface treatments 3 The limit switches on the Motor Bracket Assembly automatically prevent motor stall priorto end oftravel Motor Bracket Assembly 4 Required to assure electrical continuity initiates from Upperto Lower Ring Retained by Limit switches 5 The conductive path to adjoining vehicle is have changed via str
58. ed cylinder when stowed Line loading may peak in areas where stiffness peaks For example if you use a MLB15 000 on a rectangular satellite that has 15 x 15 inch base plate line loading is expected to peak at the midpoint of the sides because the stiffest region is at the midpoints Engineers should design structures to the maximum allowable line load of the adjoining structures and ideally have a design that minimizes the extremes of line loading Such a design is also structurally efficient as shown in the cylindrical satellite shape on the right side of Figure 5 22 Bolted joints to adjoining structures should be designed at a minimum to react the expected line loads Figure 5 22 A round separation system and a square satellite can create high line loading 10 July 2014 www planetarysys com Page 29 of 97 2000785E User s Manual for Mark II Lightband Planetary Systems Corporation 5 12 Flatness and Parallelism Prior to joining to the Lightband the surfaces adjoining the Lightband should be flat to the specification defined in Table 5 1 2000 my YED 2667 Ix 2000 vw IIH TD ser Xu 1 Figure 5 23 A Lightband attached to a launch vehicle cone When the adjoining vehicles are extremely warped or surfaces are not parallel an attempt to join the separation system to both adjoining structures may simply break the Lightband Joining a separation system to only one adjoining structure will generally not increase stress
59. educes the response of the system at vibratory resonance To estimate the damping ratio of the Lightband results of vibration tests of the Lightbands with mass mock ups attached were used g r 4 Control accel ee OM EI os t M mi Wi Wr s m Figure 5 26 Vibration test of a Lightband with a mass mock up Since the damping of the mass mock up and the many bolted joints is included the measured damping ratio must be higher than the Lightband damping To arrive at a conservative recommended Lightband damping ratio the test measured damping ratios were reduced by 5096 to arrive at the recommended values at shown in Table 5 7 Axis AXis ZeAxis O Measured damping ratio d 0 025 0 069 0 063 Hecommended damping ratio d 0 013 0 035 0 032 Table 5 7 Damping Ratio The damping ratio can be calculated if one knows the quality factor q of a system s response at resonance Quality factor is the ratio of output response level to the input level In this case the input and output levels are of the unit gravitational force The quality factor is defined in Equation 3 3 Where d is the damping ratio 10 July 2014 www planetarysys com Page 31 of 97 2000785E User s Manual for Mark II Lightband Planetary Systems Corporation 5 14 SoftRide and Lightband The SoftRide Isolation System is a spacecraft vibration and shock isolation system designed to reduce launch vehicle induced
60. edule for non custom Lightbands Some Lightbands have been delivered 4 months ARO however the price is higher Customers can receive status reports of the above schedule events 21 1 Standard Lightband Deliverables The standard items delivered to the customer are The Lightband s The production log provides detailed traceability of parts procedures and other materials Copies of all as run test procedures and reports Certificate of conformance Training on Lightband operation DITS UO IN e Whenever a Lightband is required that is different i e requires custom features additional testing different procedures different compliance documents etc from one presented in this document it is by definition a customized product In this case PSC will present the following schedule and terms and conditions Prospective users should be aware that the cost and schedule of customized Lightbands is often substantially greater than the standard product presented in this document Deliverables rom PSC eo Phase Complete specification of the customization Assembly drawings Cost plus fixed fee All test procedures or time and Custom tooling materials Manufacturing and test schedule All success criteria Anomaly reporting Test results a ba to be determined or any change in Cost plus fixed fee to Phase I requirements that exceeds specifications in etc or time and Phase materials Table 21 2 Customizat
61. emperature is 35 C Extensive testing has shown the ideal operating deployment temperature is 35 C This temperature minimizes time to initiate and energy to initiate At lower temperatures the energy and time to initiate increase because the increase in viscosity of Lightband lubricants and CTE mismatches of the Lightband s components These result in an increase preload of dynamic mechanized junctions However the Motors winding resistance decreases at lower temperatures allowing more current to flow to the Motors and thus more torque to drive the initiation 80 1 00 06 Pressure spikes as software shuts down after completion of the 7th thermal cycle the chamber was held at partial vacuum over night The pump is restarted and the pressure is brought back down to requirement J to perform separation 1 00E 05 AAA 4444 HA MA 1 00E 03 Chamber is vented and test item is stowed 60 A o 1 00 02 30 H 1 00E 01 o E amp o I 320 1 00 00 S p amp 10 1 00E 01 i 1 J 1 1 oH B 1 00E 02 i i T 4 10 A rl N 1 00E 03 A 1 h L h 20 i 1 00 04 I 1 1 1 NV NEA 4 30 3 MCA Munt X woe 1 00 05 1 4 4 e wes 4 Sew uem 1st Separation 40 1 00E 06 0 120 240 360 480 600 720 840 960 1080 1200 1320 1440 1560 1680 1800 1920 2040 2160 2280 2400 2520
62. engineers to use a larger diameter than required to gain margin with only a small increase in weight M rss Lateral Frequency Moment gcc CG and weight supported by b Lightband CG distance above bottom Ayial load ateral loa of Lightband Recommended high stiffness Discouraged low frequency and strength margin and strength margin Figure 9 2 Larger diameter Lightbands are stiffer and stronger than smaller diameters Consider an isolation system Isolation systems can substantially attenuate detrimental vibratory environments Furthermore they typically reduce natural vibratory frequency Determine strength requirements Calculate maximum line load from Section 5 11 and overall loading Verify that loads required to attain those line loads are less than maximum loads shown in Table 5 1 It is not sufficient only to be below maximum line loading it is also necessary to be below maximum loading Determine cyclic loading and fatique requirements Determine if the vibration environment will cause an exceedance of allowable line loading Determine the number of Separation Springs no separation velocity requirement exists the typical method is to select enough springs to attain a relative velocity of 0 3 meters per second If you require more Springs than allowed in Table 5 1 contact PSC for further discussion The minimum number of Separation Springs should be six 6 regardless of Lightband
63. er of mass of the separating vehicle Equation 4 assumes the adjoining vehicle is many times more massive greater than 10X and has many times more inertia gt 10x than the separating vehicle It also assumes the pre separation rates are all zero Rotation Rate vs CM Offset 7 EE a 0 000 0 002 0 004 0 006 0 008 0 010 0 012 0 014 CM Offset d m pipe a degs Figure 5 31 An illustration of Equation 4 10 July 2014 www planetarysys com Page 37 of 97 2000785E User s Manual for Mark II Lightband Planetary Systems Corporation The Separation Spring configuration may be adjusted on the Lightband so the Springs as a sum push through the CM However it may be easier to move the CM The lower the v required the lower the rotation rates Sometimes rotation rates are desired as this may beneficially produce even solar heating dynamically stabilize the vehicle or counter pre separation rates In such cases relocating the Separation Springs to one side of the CM or allowing the CM offset d to be significant affects the desired rotation rates mM mM v x m M 2nE 6 Equation 6 can be used to calculate the number of Separation Springs required given a particular desired delta velocity between the payload and the final stage Where S is the number of Separation Springs required m is payload mass M is final stage mass v is the relative velocity between m
64. erally PSC neither supplies nor lends out GSE Production drawings Description available to A structure that has the same mass and center of mass as the payload Caution structures such as these tend to exhibit low damping values and at resonance substantially increase response Force limiting or notching of input may be required to prevent damage Precise machining is required to meet flatness requirements Mass mock ups with the Lightband bolt pattern Fastens to the Upper or Lower Ring Useful to attenuate flatness issues of Transition Ring adjoining structures allow access to PSC Part fasteners to Lightband and to allow a Lightband to operate The Lightband must be attached to an adjoining structure or it will flex too much when stowing Number 2000741 The interface between an electro dynamic exciter and the Lightband or a Transition Ring Vibration Adapter Plate Lightband Controller Used to stow deploy and set for flight Components the Lightband Requires a cable oscilloscope between the Lightband and the power supply controller with DB 9 connectors relay time amp ammeter 10 July 2014 www planetarysys com Page 86 of 97 2000785E User s Manual for Mark II Lightband Planetary Systems Corporation Production drawings Description available to PSC engineers use this in the field to automatically deploy stow and set for flight the Lightband for high value Lightband Test progr
65. es before inspection by PSC is required This includes about 25 separation tests that PSC completes prior to shipping to the customer Thus the customer may typically separate the Lightband about 35 times Stowing is much more strenuous on the Motor Bracket Assembly than deploying The Lightband s Motor Assembly consumes about 60 Joules of energy when stowing while it only consumes about 3 Joules when deploying After the 60 cycle the Lightband must be inspected by PSC Engineers to determine the wear rate and the amount of lubrication remaining Using the minimum voltages on all operations maximizes the Lightband s cycle life Lower voltages produce lower currents meaning torque and stresses in the parts connected to the Motors are minimized In qualification and development testing the Lightband has been shown to reliably stow and deploy several hundred times while simultaneously being exposed to extreme temperature cycling 25 to 90 C 5 17 Alignment Aligning Upper Ring amp Lower Ring Several features act sequentially to guarantee alignment of the Upper and Lower Ring prior to the stow event In order of operation these features are 1 The Separation Spring s conical tip mates with the Upper Ring s accepting holes The telescoping features of the Separation Springs guide for about 0 6 inches of travel The cut out for the Motor Bracket Assembly in the Upper Ring only allows one rotary orientation of the Upper Ring The polymer guide pins in t
66. f the Lightband cannot be stowed it cannot fly However the Lightband will deploy and set for flight with one Motor A flex circuit connects the Limit Switches and Motors to the DB 9 socket connector fastened to the Motor Bracket Section 6 of this document describes electro mechanical operation of the Lightband Motor A Angular Contact Bearings Bevel Gears Planetary Gear Ball Screw Sliding Tube Motor Bearing Deploy End Plate Stow Limit Switch Side B Stow End Plate Deploy Limit Switch Linear Way Side B Figure 5 9 Motor Bracket Assembly shown in the stowed state 10 July 2014 www planetarysys com Page 17 of 97 2000785E User s Manual for Mark II Lightband Planetary Systems Corporation Figure 5 10 Motor Bracket assembly shown in the set for flight state Sliding Tube Movement Direction Figure 5 11 Motor Bracket assembly shown deploying Figure 5 12 Motor Bracket assembly shown in the deployed state 10 July 2014 www planetarysys com Page 18 of 97 2000785E User s Manual for Mark II Lightband Planetary Systems Corporation 5 4 Dimensions Lower Rind DB Upper Rind Lower Ring T YiB Figure 5 13 Top view of Lightband see Table 5 1 for variable dimension values The dimensions shown in Figure 5 13 and Figure 5 15 as variables vary with diameter and are defined in Table 5 1 Dimensions C and D include the separation eve
67. h test As such these values incorporate any peaking associated with the discontinuity of the Motor Bracket assembly Because the Motor Bracket is located in the space of one Leaf Assembly the distribution of load is discontinuous at the Motor Bracket Assembly By application of Equation 1 and Equation 2 you are naturally incorporating the load peaking associated with the Motor Bracket Assembly Therefore you do not need to additionally apply a peaking factor for that purpose Engineers frequently use PSC Document 2001097 Line Load Velocity and Tip Off Calculatorto automate loading computations See Figure 5 21 Line Load Calculator Axial Acceleration g Lightband X 7 0 Lateral Acceleration g Lightband Y or Z 3 0 Factor of safety 1 25 Mass Ib 1 100 Axial Force Fx lof 9 625 Lateral Force V lbf 4 125 Number of Fasteners n 60 Center of mass from Lightband C S CMx in 30 Bolt Circle Diameter D in 38 81 Moment in lo 123 750 Max Actual Allowable Margin Maximum Axial Line Load P lof bolt 373 0 1 880 0 4 04 Maximum Shear Line Load Q Ibf bolt 137 5 774 0 4 63 Figure 5 21 Line load calculator example a 1 100 pound satellite mounted on a MLB38 810 From PSC Document 2001097 10 July 2014 www planetarysys com Page 28 of 97 2000785E User s Manual for Mark II Lightband Planetary Systems Corporation It is useful to observe that the Lightband behaves structurally like a thin wall
68. he Lightband is 0 0070 x 0 002 O At least one Separation Connector is required to assure conductivity because the Upper Ring is anodized The conductive path is through the Separation Connector shells and EMI gaskets in the Separation Connector Assemblies Grounding to adjoining structures is achieved by using conductive fasteners from the Lightband to adjoining structures The conductive shell of the DB 9 connector is fastened mechanically and electrically to the lower assembly of the Lightband 6 11 Surface Charging Because the Upper Ring has an anodized surface it may be susceptible to localized surface charging It is grounded to adjoining structures at each attachment bolt location about every two inches along its circumference The shells of the Separation Connectors are grounded at their mechanical interface to the Upper Ring via a local spot face where the anodized surface is removed The Lower Ring is not anodized and its surface is fully conductive 6 12 Radiation Sensitivity The Lightband is not sensitive to radiation The Lightband does not possess any integrated circuits or semi conductors There are no diodes capacitors or resistors 6 13 Static Sensitivity The Lightband has no static sensitive parts 20 Source PSC Document 2002305 10 July 2014 www planetarysys com Page 52 of 97 2000785E User s Manual for Mark II Lightband Planetary Systems Corporation 7 Thermal Properties 7 1 Operating the Lightband Motors in a V
69. he Separation Connector halves mate together The shells of the Separation Connector if attached align The shear pins of the Upper Ring and their accepting grooves in the upper link of the Leaves align together The Leaf lips align with their accepting grooves in the Upper Ring o or pe m It is estimated that the variation in alignment in the above process is about 0 001 inches any direction Aligning with adjoining structures The bolt patterns of the Upper and Lower Rings are concentric to within 0 01 inches when the Lightband is stowed The rotational tolerance of the Upper and Lower Ring is 0 1 degrees when stowed Aligning the Lightband to another structure can be accomplished by using flat head fasteners when the adjoining structure is threaded or gage pins when the adjoining structure has a flange with through holes A flat head fastener has a conical feature that tends to force alignment However flat head fasteners should not be used to permanently fasten the Lightband to an adjoining structure A gage pin of 0 275 0 005 inch diameter is the nominal diameter that would form a slip fit to the holes on the Lightband 10 July 2014 www planetarysys com Page 33 of 97 2000785E User s Manual for Mark II Lightband Planetary Systems Corporation 5 18 Materials and Surface Treatments Material surface finish may be used to determine rates of radiative heat transfers and surface charging of the Lightband and attached structures All materia
70. he definition in MIL STD 1540 However PSC s testing of the Lightband does not include the wiring harness which as noted earlier can weigh as much as or more than the Lightband GSE Transition Rings are fastened to the Lightband during testing to mimic flight like structural thermal and dynamic boundary conditions PSC writes executes and approves all test plans PSC also takes any corrective action if anomalies arise after required customer notification If requested customers are supplied the test plans prior to test start The customer furnished wiring harness is not included in the standard testing Prior to these tests PSC completes several bench top separation tests in order to tune in the preload force of the Retaining Ring There is no set sequence for these four tests Generally customers are permitted to send one 1 person to attend all testing at PSC Arrangements must be made with PSC ahead of time if a customer representative is to attend a test Test engineers may opt to employ a Load Cell Link connects the Sliding Tube to the Retaining Ring to monitor Retaining Ring preload during test Following testing the Load Cell Link is replaced with an un instrumented Link Standard or Motors powered A B Both at Typical Number of Separations Optional Test Voltage V Performed Bench top separation Standard Both28 Vibration Test Standard Both28 Thermal Vacuum Test Standard A24 B24 aum Standard A32 B32 Both32 A28 B28 Both28
71. hese tests and procedures after receiving the Lightband Test or procedure Objective Remarks and cautions Will the Lightband be overloaded at methods employed Verify the initiation circuit and power system Ensure Lightband operation procedures are from the launch vehicle will properly initiate being followed by using the latest revision of the Lightband Verify adjoining vehicle will PSC Document 2000781 MkII MLB receive the proper signal upon separation Operating Procedure Table 19 1 Testing and other procedures Electrical initiation test Figure 19 1 Electro mechanical fit check and a separation test with a Lightband 19 1 Designing the Wiring Harness As discussed in other sections of this document it is essential to model the wiring harness which PSC does not provide to and through the Lightband The harness can easily weigh as much as the Lightband and substantially obscure access to the Lightband fasteners It can also interfere with adjoining structures if formed harness radii are not precisely specified PSC recommends the simplest possible harness design using the smallest quantity of Separation Connectors and switches 10 July 2014 www planetarysys com Page 85 of 97 2000785E User s Manual for Mark II Lightband Planetary Systems Corporation 20 Ground Support Equipment GSE Several pieces of GSE have been useful to customers in the past In the cases noted in Table 20 1 PSC can supply production drawings Gen
72. hicle loads 10 July 2014 www planetarysys com Page 32 of 97 2000785E User s Manual for Mark II Lightband Planetary Systems Corporation Isolation systems add mass that is usually negligible compared to the spacecraft mass In fact the mass added by SoftRide is often nullified because the Lightband has a lower mass than other separation systems Isolation systems require a displacement stroke in order to attenuate dynamic loads Typical axial strokes in flight have been in the 0 2 to 0 4 inch range Lower frequency higher performing isolation systems require more stroke than higher frequency isolation systems 5 15 Fatigue Limits Fatigue failure is generally defined as failure due to cyclic loading Fatigue failure is typically manifested in a flight stack as a loss of preload in fasteners a breakdown of surface treatments at separable interfaces or cracking of materials Fatigue can be induced by static loads sine vibration random vibration and shock impulses It can be locally amplified when dissimilar structures ex round to square are joined to the Lightband The Lightband s fatigue limit in relation to applied line load is shown in Figure 5 29 110 100 90 80 70 60 50 40 30 20 10 0 10 100 1 000 10 000 100 000 1 000 000 Fatigue Life Cycles Percent of max line load Figure 5 29 Lightband fatigue limits and line loading 5 16 Deploy and Stow Cycle Life The Lightband can be stowed and deployed 60 tim
73. icial in the assembly process because fasteners are easier to install but limits the capacity of fasteners to guarantee alignment of structures to the Lightband For 15 inch diameter Lightbands PSC recommends the use of reduced head diameter 14 28 socket head cap screws to fasten the Lower Ring to adjoining structures This prevents the interference between the fasteners and the Leaves described in the Lightband Operating Procedure The head diameter should be 0 340 inches See Section 20 00 25 SHC screws and small pattern washers NAS620C416 etc recommended 10 screws can be accommodated with appropriate shoulder washers Figure 5 19 1 4 inch fasteners from Lightband to adjoining structures Smaller fasteners such as 10 are also acceptable for use Hex head fasteners will not work because there is insufficient room for tools to grip the hex head Fasteners must be installed at every location in order to integrate the Lightband Do not skip a bolt as this will substantially decrease strength and stiffness of the Lightband The thermal extremes of the bolted joint often drive the selection of fasteners Users anticipating temperatures beyond 10 to 50 should examine the pre load changes associated with coefficient of thermal expansion CTE mismatch In the past missions on the Space Shuttle have driven bolted joint design to extremes because joints are expected to survive landing loads at very low temperature 40 C NASA s
74. ify the location configuration of Separation Springs to null out rotation rate torques during Separation Reliability tests This tuning process is done when flight hardware is acceptance tested See Section 15 1 3 This testing is performed on all flight Lightbands Figure 5 34 is a sample of Separation Reliability test results on an MLB11 732 18 5 0 4 0 3 0 2 0 1 0 0 0 Rotation Rate deg s 1 0 2 0 3 0 4 0 5 0 10 July 2014 Separation Reliabilty Test Results Qo a a c me a a e eum S a a a ae a 1 2 3 4 5 6 7 8 9 10 Separation Trial No Pitch ZLB 9 Roll XXLB Velocity Figure 5 34 Example of test results from separation reliability test performed on an MLB11 732 www planetarysys com 2 0 1 8 1 6 1 4 1 2 1 0 0 8 Separation Velocity ft s 0 6 0 4 0 2 0 0 Page 39 of 97 2000785E User s Manual for Mark II Lightband Planetary Systems Corporation When several payloads are on the same launch vehicle engineers can minimize the possibility of re contact by varying the separation velocity and direction This can be a complex calculation Angling the payloads so they push through the center of mass reduces rotation rate torques and the possibility of r
75. ion Hammer Figure 15 11 A shock test of a MLB11 732 performed on PSC s shock test fixture 10 July 2014 www planetarysys com Page 78 of 97 2000785E User s Manual for Mark II Lightband Planetary Systems Corporation 16 Qualification Testing of Lightbands Various diameters of Lightbands have been put through qualification environmental test on multiple occasions Qualification tests of Lightband diameters shown in Table 5 1 are generally not required and should be considered custom work This section is intended as a reference to present proven limits of the Lightband during previous environmental qualification tests 16 1 Vibration Qualification Test 16 1 1 MLB15 000 Vibration Qualification Test Tested vibration limits of a 15 inch diameter Lightband are shown in Table 16 1 Table 16 2 and Figure 16 1 WARNING These vibration levels should not be applied to the Lightband when the Lightband is supporting a substantial mass without carefully considering the effects of resonance and structural impedance The prescribed environment below is for the Lightband alone When the Lightband is supporting a structure engineers must determine how the vibration environment will generate line loading and how much of the Lightband s fatigue life will be consumed L9 ENS 00260 0260 0 7960 3 07900 100 _ 000 4810 40 01990 000 151 000 11642 1079
76. ion schedule Upper Interface Plane 50 19 SHC Screws will also be accomodated with appropriate washers 50 25 SHC Screws and Small Pattem Washers 5620 416 etc recommended Lower Ring Interface Plane Figure 21 1 Custom work example modified Upper Ring for an MLB31 600 Mk Il used on the IBEX program 10 July 2014 www planetarysys com Page 88 of 97 2000785E User s Manual for Mark II Lightband Planetary Systems Corporation 21 2 Lightband STEP Files STEP files of Lightband assemblies can be made available to prospective users and customers These include models of the Lightband deployed and stowed These models allow the generation of unique spring Separation Connector and switch configuration PSC reserves the right to move spring locations to satisfy rotation rate requirements when PSC completes separation reliability testing on flight Lightbands 21 3 Assembly drawings PDFs of assembly drawings can be made available to customers 21 4 Finite element models of Lightbands PSC has developed test verified finite element models FEM of Lightbands Contact PSC for further information 10 July 2014 www planetarysys com Page 89 of 97 2000785E User s Manual for Mark II Lightband Planetary Systems Corporation 22 Purchasing a Lightband Lightband prices are listed on the GSA Schedule Contact PSC directly to receive the most up to date prices Standard payment schedules are shown in Table 22 1 See Sectio
77. itch Rate deg sec 0 000 0 371604 0 100 Velocity 1 160 1 165 L 170 1 175 1 180 1 185 E 190 1 195 1 200 1 205 1 210 1 215 1 220 1 225 1 230 235 1 240 1 245 d 250 255 1 26 1 81568 Velocity misec Time sec 0 553419 gin Channel Energy J L C i 2 O Yaw Rate degisec Figure 15 1 Typical test data from a Lightband separation test 10 July 2014 www planetarysys com Page 69 of 97 2000785E User s Manual for Mark II Lightband Planetary Systems Corporation 15 1 Standard Acceptance Tests Each test in this section is performed on every flight Lightband built by PSC The test parameters default to those shown herein Any adjustment to these parameters is considered custom work 15 1 1 Vibration Test Location Qualified Vibration Test Facility in DC metro area Objective Verify workmanship Test Description During this test the test item will be exposed to a controlled random vibration profile in three orthogonal axes Upon completion of vibration the test item will be separated and then formally inspected to verify that it still operates nominally Standard Levels Table 15 2 and Figure 15 2 show the nominal acceptance test random vibration profile These values are derived from MIL STD 1540 E Test Requirements for Launch Upper Stage and Space Vehicles SMC THR 06 1 1 Number of separations One 1 following
78. launch vehicles and to separate elements of launch vehicles The Lightband is offered in a range of sizes from 8 to 38 inch bolt circle diameter The content of this user s manual is based on the experience of providing more than 80 separation systems to commercial government and university customers both domestic and international whom launch payloads on a broad range of orbital and sub orbital launch vehicles The Lightband is a patented Commercial Off The Shelf COTS technology It is made with materials and methods consistent with high reliability and Class A space flight hardware This is the user s manual for the Mark Il Motorized Lightband only The can be uniquely identified from other Lightbands On the motors are on the outer diameter of the unit if Mark Motorized Lightband MLB Payload separation system 40 on orbit operations TRL9 8 00 to 38 81 inch diameters Canisterized Satellite Dispenser CSD Cubesat deployer Flight heritage 3U 60 120 amp 270 sizes Figure 2 1 MLB separates Space Vehicles from Launch Vehicles CSD is another PSC product for smaller space vehicles J Figure 2 2 Two of NASA s lunar GRAIL satellites built by Lockheed Martin separate from a Delta Il in 2011 using 2X MLB19 848 10 July 2014 www planetarysys com Page 6 of 97 Planetary Systems Corporation 2000785E User s Manual for Mark
79. lo analysis PSC document 2001071 was used to determine this tolerance It includes variations in stiffness spring dimensions and assembly dimensions This variation is eliminated by virtue of measurement of kinetic energy during separation reliability testing 10 July 2014 www planetarysys com Page 36 of 97 2000785E User s Manual for Mark II Lightband Planetary Systems Corporation 5 22 Rotation Rates Separation Velocity and Separation Springs Rotation rates are induced by the distance between the CM and the center of the spring force Rotation rates may be about any axis of a space vehicle as a result of the separation event When rotation rates are to be minimized the nominal requirement is 0 0 1 0 degree per second per axis When the sum of the Separation Spring force is not acting through the center of mass of the adjoining structure rotation rates will result Rotation rates can be estimated via Equation 4 There are many variables that contribute to this rate and several simplifying assumptions have been made to compensate Only Separation Reliability testing can produce verifiable values for rotation rates Payload Mass m and inertia 1 Figure 5 30 CM offset and rotation rate mvd Where W is the rotation rate angle per unit time m is the mass of the payload v is the relative velocity d is the distance between the CM and the resultant location of the Separation Springs 15 the mass moment of inertia about the cent
80. ls in the Lightband are low out gassing as defined by ASTM E 595 total mass loss TML is less than 1 096 and a collected volatile condensable materials CVCM is less than 0 196 All of the materials in the primary load path are highly resistant to stress corrosion cracking SCC as defined by MSFC STD 3029 In Primary Highly Component Name Part Number Load Resistant Magnetic Vendor Path to SCC NI AI Aly 7075 T7351 per AMS os oe Conv color gold per Mil DTL Lower down Varies by diameter A 2502 or AMS 4078 5541 Cl 3 Al Aly 7075 T7351 per AMS zia RS as Anodize per MIL A 8625 Type Al Al 6061 T6 per AMS QQ A Electroless Nickel per AMS C Al Aly 6061 T6 per AMS QQ A Electroless Nickel per AMS C Al Aly 6061 T6 per AMS QQ A Electroless Nickel per AMS C EI EET 250 11 pf ef ret Sees 26074 Class 4 Grade B Leaf Retaining Ring PH 15 7 Mo Stainless Steel EN Ae vales 6061 T6 per AMS QQ A DIE Anodize per Mil A 8625 Type Retaining Ring Varies by diameter 250 11 pon oe Ill Class 1 PSC Motor Bracket 4000394 Al Aly 6061 T6 per AMS QQ A N N Hard Anodize per Mil A 8625 Type PSC 250 11 IIl Class 1 Al Aly 7075 T7351 AMS QQ Hard Anodize per Mil A 8625 Type HE TT 250 12 Il Class 1 E Z Z Z lt H 4 BeelGear 4000494 300 Series Stainless Steal Hide N Proprietary Al Aly 6061 T6 per AMS QQ A Hard Anodize per Mil A 8625 Type UOS 250
81. ments and added to table 1 Added detail of a roll inducing mechanism Added acknowledgments Added sectional view of Separation Spring Added flow diagram showing manufacturing process Added flow diagram showing separation reliability test process Added table showing voltages used during manufacturing and test process to initiate Lightband Added detail of optimal flange design in adjoining structures Many editorial edits and spelling corrections C 01 Jun 12 WH AZ WH Added applicable patent numbers to front cover Added pictures of GRAIL separation and STP S26 in Section 2 Added Technology Readiness Level 9 discussion in Section 3 Updated Lightband flight history Updated Figure 5 13 with latest stay out zones Updates to mass and stay out zone in Table 5 1 Updated Mass of Separation Springs in Table 5 10 Updated Separation Connector graphics in Table 5 10 Increased line load limits IAW PSC Document 2002319 in Section 5 11 Changed energy E to 1 02 J in Figure 5 33 Updated stow schematic in Figure 6 7 Updated SFF schematic in Figure 6 8 Updated deploy schematic in Figure 6 9 Added 2001025 Separation Connector Data Sheet in Section 6 4 Updated shock levels in Section 8 Updated accelerometer photos in Section 8 Added detail of 2000770 MkII Motorized Lightband Failure Modes and Effects Analysis in Section 12 Added Section 18 on Lightband refurbishment Updated photos of shipping procedural steps in Section 23 Updated formatting amp
82. n 9 for information on selecting and specifying a Lightband to best meet your mission s requirements vent Payment Pa Receipt of order 50 Build complete review BCR completion Shipment Table 22 1 Standard payment schedule 10 July 2014 www planetarysys com Page 90 of 97 2000785E User s Manual for Mark II Lightband 23 Lightband Training Lightband training for up to 5 users at PSC s facility is included in the price of the Lightband Operation of the Lightband by any customer personnel is prohibited until he or she has received training The training session lasts approximately 4 8 hours and can be performed at another location at an additional cost Planetary Systems Corporation The importance of the training session cannot be overstated In addition to learning how to operate the Lightband customers will be able to discuss their expected integration scenario PSC s trainers will help uncover any unforeseen issues during integration and discuss all possible solutions By having this discussion ahead of time customers will streamline the Lightband integration process and prevent expensive program delays At a minimum the following topics will be covered during the training session 10 July 2014 How the Lightband works Best practices Warnings and warranty violation items Required materials Handling precautions Mechanical attachment procedure Stowing procedure Setting for flight procedure Deploying procedure
83. n ie re ese i seltene se esse sentes rss ee enses re nns 46 6 7 SEPARATION PARAMETER VARIATION niit Sein S d t s Seem nea 49 Oo a a a a A 51 69 SHMOREBBEBSIVIOLOE 52 6 10 EIGHIBAND ELEC IRICAL RESISTANG E o iste 52 6 11 NIORT T O 52 6 12 EIAN A AA H 52 6 13 52 T MRERMAL PROPER TES TEES P 53 Vk OPERATING THE WIGH BAND MOTORS INA VACUUM ect iet eapaadcectdatyoendar EESO eec 53 T2 SUBVIVAL AND XOBEBATINGAEIMITS turo eor vit o doe ox vn a E pe Une EE Ege ibas evo dead Den edi ibas eve dicio se d 53 7 3 ABSORPTIVITY AND EMISSIVITY eee ecu See e note Maga oe CREER YE ee ga Yee ES EET A PONE EE cians vedas tee ea YES S OE PUR ugs 54 742 CSPHEBRMAITAESISTANCI d D ET Mt LR EET 54 7 5 NOMINAL THERMAL RESPONSE CL tbc hiis bote ic DEL LA occ E ie aad LE 54 TO SUBERMALE GRADIENTS AND TRANSIENTS te tec eta deoa mto ei t
84. ness to the halves of the Lightband and the adjoining vehicles The harness can be attached or removed from the Lightband in both the stowed and deployed states The Separation Connectors and Switches are designed to be attached to the Lightband from the outside of the ring while deployed but can also be installed when stowed Figure 6 4 Through holes on the outer lip of the Lightband Upper and Lower Ring exist for routing tie wraps to support harnesses While the harness can be passed through the Leaves in the lower assembly of the Lightband doing so creates a substantial mechanical integration difficulty Getting tools at the fasteners to adjoining vehicles becomes difficult or impossible Internal harnesses should be avoided because of this access issue 10 July 2014 www planetarysys com Page 43 of 97 2000785E User s Manual for Mark II Lightband Planetary Systems Corporation 6 4 Separation Electrical Connectors The Separation Connector is designed by PSC exhibits essentially zero friction during separation so as to ensure low rotation rates Most electrical connections are designed to stay together an attribute separation systems must avoid A full description of PSC s Separation Connectors can be found in PSC Document 2001025 Separation Connector Data Sheet a C WANICAL INTERFACE Figure 6 5 Separation Connector as described in PSC Document 2001025 Separation Connector Data Sheet The connectors have been extensively tested in sho
85. ng Separation System Testing Proceedings of the 36 Aerospace Mechanisms Symposium Glenn Research Center May 15 17 2002 Lessons Learned Designing A Spherical Satellite Release Mechanism 39 Aerospace Mechanisms Symposium Huntsville Alabama May 2008 Criteria for Preloaded Bolts NSTS 0837 Rev A July 6 1998 Table 26 1 Procedures Documents and Publications 10 July 2014 www planetarysys com Page 94 of 97 2000785E User s Manual for Mark II Lightband Planetary Systems Corporation 27 Warranty The Lightband warranty is defined in PSC Document 1001015 Warranty MLB 10 July 2014 www planetarysys com Page 95 of 97 2000785E User s Manual for Mark II Lightband Planetary Systems Corporation 28 Glossary ARO After receiving order Bench top testing A separation test of the Lightband on a bench top Rate and velocity information are not recovered Build Complete Review BCR Verify product assembly is complete and hence ready for test This includes bench top separation CM Center of mass CTE Coefficient of thermal expansion Electro dynamic exciter EDE A machine used to apply vibratory loading EMF Electromotive Force End Data Package EIDP As run test plans production log and certification Engineering development unit EDU A Lightband designated for use on the ground to allow engineers to use flight like hardware EDU are not exposed to standard testing they only receive several bench top separation te
86. nitials 2 Initials g Are all accessible fasteners tight can only Choose an item be loosened with tools n Is the staking on fasteners not delaminated Choose an item by more than 25 of any fastener s circumference Are the Spring Plunger tips protruding from a an item the Upper Ring by 0 13 0 03 inches Do the Separation Connector Pins if an item attached have visually uniform free pin heights rev C only and protrude past the profile of the Upper Housing Does the Separation Switch plunger if 7 attached compress and elongate 0 280 0 040 inches Is the staking not delaminated Do the Separation Springs measure 2 1 0 1 Choose an item inches in the elongated state Do the Separation Connector Pins if Choose an item D 10 attached have visually uniform free pin cc heights lt 9 Does the Separation Switch plunger if Choose an item 11 attached compress and elongate 0 280 0 040 inches e e omm Do the four Limit Switches change Choose an item resistance more than 1 0 MQ when depressed Is the Lightband free of any yield or damage Choose an item that prevents nominal operation Table 17 1 Standard inspection of Lightband 3 Excerpted from PSC document 2001066B 10 July 2014 www planetarysys com Page 83 of 97 2000785E User s Manual for Mark II Lightband Planetary Systems Corporation 18 Lightband Refurbishment After a Lightband has been cycled stow set for flight
87. nt when the Retaining Ring and Sliding Tube snap inward The dimensions shown as constants do not vary by diameter The customer supplied wiring harness is not shown Harness design discussed in Section 6 3 can substantially increase the volume associated with the separation system Upper Ring Mounting Flange e en 0 17 Lower Ring Mounting Flange Figure 5 14 A sectional view of a 15 inch Lightband 10 July 2014 www planetarysys com Page 19 of 97 2000785E User s Manual for Mark II Lightband Planetary Systems Corporation Figure 5 15 The deployed or separated view The Springs and Switches are shown fully elongated 10 July 2014 www planetarysys com Page 20 of 97 2000785E User s Manual for Mark II Lightband Planetary Systems Corporation 5 5 General Capabilities and Dimensions MLB bolt circle diameter 0 01 in 8 000 11 732 13 000 15 000 18 250 19 848 23 250 24 000 31 600 38 810 Number of fasteners n 12 18 20 24 28 28 32 36 48 60 Stay out Dimensions 0 02 in 5 Mass 5 Ibi 1 Center of Mass 0 1 in 1 Inertia 10 Upper Assembly Lower Assembly Total X assembled Yip assembled Zip assembled X Upper Assembly Yig Upper Assembly 2 Upper Assembly X Lower Assembly Yig Lower Assembly Z pg Lower Assembl lx assembled assembled lzz assembled ho upper assembled 0 86 1 37 0 00 316 5 140 4 180 4 85 3 43 5 1 266 7 3 051 9 577
88. ocument 2002205 The bracket reacts the force of the plunger Includes mounting hardware Induces rotation about axis Suggested quantity is 1 pair per Separation Spring Includes mounting hardware Does not include tie wrap Table 5 10 Subsystem Weights 10 July 2014 www planetarysys com b PT CCA TETT J Page 35 of 97 2000785E User s Manual for Mark II Lightband Planetary Systems Corporation 5 21 Component Spring Parameters Several Lightband subsystems contain springs that effect separation velocity Extensive testing has shown about 90 percent of the spring energy shown in the table below is available to create separation velocity It is assumed that the missing 10 percent of the stored energy is converted to heat from the effect of sliding friction during the separation event Spring Before After Constant N mm Separation Separation Used to create the Separation separation velocity Sprin Has telescoping di 7 features PSC PNs 2001071 and 2001065 tio These springs push the Leaves out of the Upper Ring They do Spring not influence Plunger separation velocity Typically one spring plunger is used per Leaf Assembly Data for mated pair Separation Each connector has 15 Connector spring plunger contacts Separation Each Switch houses Switch i one spring plunger Table 5 11 Spring parameters Monte Car
89. om Page 50 of 97 2000785E User s Manual for Mark II Lightband Planetary Systems Corporation 6 8 Back EMF of the Motors The Motors are connected to each other via bevel gears Motors behave like direct current generators while running 1f only one Motor is powered the other will generate a voltage almost as high as the voltage of the powered motor but zero current Figure 6 13 Only Motor A is powered and thus Motor B indicates a voltage but not a current 10 July 2014 www planetarysys com Page 51 of 97 2000785E User s Manual for Mark II Lightband Planetary Systems Corporation 6 9 Shorted Motors When one of the Motors is shorted the shorted Motor will act as a damper consuming most of the energy that the other Motor generates The time to initiate will increase significantly Do not short the motor s Figure 6 14 shows the difference in time to initiate when a Motor is open versus shorted An increase in time to initiate is clearly apparent at multiple temperatures Voltage vs Time to Initiate For Single amp Shorted Motors 47 C 4 C Shorted 23 923 Shorted 102 102 C Shorted 2 o gt 0 4 0 6 Time to Initiate sec Figure 6 14 Voltage vs time to initiate at various temperatures with a single Motor or a single shorted Motor at S10 Torr 6 10 Lightband Electrical Resistance The resistance from the upper surface of the Upper Ring to the lower surface of the Lower Ring of t
90. omplete Review TCR Vibration Thermal Vacuum Separation Reliability Legend X Typical number of separation tests End Data Package EIDP As run test plans production log RVM and certification Y psc 3 PSC quality engineer Lightband Training Teach customers to use Lightband Customer representative s Figure 9 1 Lightband selection and production process 10 July 2014 www planetarysys com Page 59 of 97 2000785E User s Manual for Mark II Lightband Planetary Systems Corporation The following steps should be completed by the customer in order to determine the correct Lightband size for their mission requirements PSC can provide PSC Document 2002034 Product Build Spec Worksheet as a means to rapidly communicate necessary Lightband diameter configuration and outline mission requirements to PSC Contact PSC for a copy of this document 1 2 Read this manual If you thoroughly understand the Lightband you will be in the best position to avoid costly test failures and program delays Determine stiffness requirements Select a Lightband based on your stiffness requirements Stiffness increases with the cube of diameter of the Lightband For example a 15 inch diameter Lightband is about 6 6 times stiffer than an 8 inch Lightband but only weighs twice as much The first lateral mode frequency increases with the 3 2 power of diameter On many missions payload stiffness is often barely above allowable minimums It behooves
91. onnectors the more complex and heavy the harness At least one Separation Connector is required to assure conductivity through the Lightband because the Upper Ring is anodized By default PSC provides two Separation Connectors with every Lightband If more than two Separation Connectors are required an additional cost is typically incurred Determine if Lightband Compression Tools are needed and their quantity the mass of the payload is less than total Separation Spring force a means to compress the Lightband before stowing is required This typically occurs during horizontal integration or when the payload mass is relatively small In many cases compression force cannot be applied to the payload itself PSC manufacturers Lightband Compression Tools LCTs for this purpose LCTs are a separate product that must be purchased along with the Lightband and specified at time of purchase like Separation Connectors or Switches The quantity installed is one pair per Separation Spring See Section 10 2 and Table 20 1 Complete a virtual fit check Integrate a CAD model of the Lightband check PSC website or contact PSC and verify your fit requirements Remember to include your wiring harness Also determine how you will fasten and operate the Lightband for shipment testing and final integration procedures Determine the electrical and mechanical ground support equipment GSE you may need for you use 10 July 2014 www planetarysys com Page 60 of 97 2000785
92. ore requesting it Standard Levels e Separate with one and both motors while varying voltage Separating mass Customer requirement 25 Rotation rates for payloads lt 200 Ibs 0 0 5 0 deg s Rotation rates for payloads gt 200 Ibs 0 0 1 0 deg s Separation Velocity Customer requirement 0 25 ft s CMy g Customer requirement 0 5 inches minimum testable value is 15 0 inches 0 0 0 05 inches 0 0 0 05 inches Number of separations At least 11 typically 15 10 July 2014 www planetarysys com Page 73 of 97 2000785E User s Manual for Mark II Lightband Planetary Systems Corporation Pre Test 1 Test inputs nti 3 Separating Arm Final Stage FS amp Space Vehicle Determine qty of Sep Spin qs Confiquration SV mass neededto meet V requirement Quantity and location of RequiredAV amp tolerance via analysis amp install an weights are determined in a Requiredrotationrates amp tolerance Lightband Solidworks CAD model to meet CM of SV amp tolerance mass CM and inertia Requiredinertias amp tolerances requirements During Test Tuning Build and bake the separating armlAW with the ring ee modify Sep Spring CAD model quantity amp configuration to meet AV and rotation rate requirements During Test Acceptance Separate the Lightband 10 consecutive times with all requirements being met Do not alter configuration During Test Verify Configuration
93. pecification PBS The PBS is used to collect relevant customer requirements regarding the Lightband the launch vehicle and the space vehicle Step 1 Requirement Definition or Revision Read Lightband Users Manual PSC document 2000785 Custom features GSE special tests or PBS worksheet a checklist on configuration and test levels special test requirements inspections etc Choose Standard lAW PSC Available on request document 2000785 GSA 1 Schedule or Custom Assembly drawings of custom test item s SOW SCD EDVR Test values limits and success criteria for testing Standard Sub system configuration springs switches connectors etc signed Contract or revision 4 Requirements Verification Matrix Program schedule Product Build Specification PBS Typically PSC s work in this dashed box is cost reimbursement basis Test item s description Test plans Requirements verification matrix RM Step 2 PSC s Standard Execution Procurement and Assembly Anomaly Reporting and Disposition Documentation and inspection of parts procedures and Any non compliance assembly This includes bench top separation 5 Build Complete Review BCR Verify product assembly is complete and hence ready for test Test Readiness Review TRR Verify test plans meet PBS Progress Reporting Testing Schedule Vibration 1 Thermal Vacuum 2 amp Separation Reliability 15 Test C
94. per Ring are too far from the Lower Ring or improperly aligned the Lightband will have to pull the space vehicle down and vice versa To minimize this effect a compliance spring and or a more precise control of space vehicle position in all six degrees of freedom is necessary Flatness of the adjoining surfaces should be within the flatness requirement defined in Table 5 1 If flatness requirements are not met by the structure shims epoxy or metal can be used to attain the required flatness Figure 10 4 PSC engineers perform a vertical integration CAPE ICU I 10 July 2014 www planetarysys com Page 63 of 97 2000785E User s Manual for Mark II Lightband Planetary Systems Corporation 11 Reliability Probability of Success Confidence Level 96 0 999 0 998 0 997 0 996 Table 11 1 Minimum reliability and corresponding confidence level Table 11 1 was calculated using Table 22 4 of Space Vehicle Mechanisms by Peter L Conley given approximately 1 000 no failure tests Lightbands have cumulatively been operated more than 1 500 times during testing Therefore the probability of successful Lightband separation is greater than 99 6 with a confidence interval of 97 5 At no time has a Lightband fail to separate on orbit As of the revision date of this document the Lightband has operated successfully more than 40 times in spaceflight There have been no failures to operate in spaceflight Prior to spaceflight each Lightband is sep
95. ration Switches and Connectors obscure view factors of the remaining area It should also be noted that black anodizing any component constitutes a custom Lightband and may incur additional cost and schedule duration 7 4 Thermal Resistance The thermal resistances of the Lightband vary by diameter as shown in Table 5 1 Thermal resistances for MLBs of diameters not shown can be extrapolated A full derivation is given in PSC Document 2000562 Thermal Resistance Test 7 5 Nominal Thermal Response The Lightband is intimately connected to massive adjoining structures on orbit Typically its view factor to Earth space or the Sun is low due to the density and size of adjoining structures As such the Lightband temperature is primarily driven by conduction to and from adjoining vehicles Adjoining space vehicles usually cannot tolerate temperatures outside of a 0 to 56 C band because these temperatures often exceed operating limits of propellants electronics and batteries which operate inside these vehicles 7 6 Thermal Gradients and Transients The Lightband has been separated while exposed to a substantial temperature differential between the Upper and Lower Rings Section 4 2 of PSC Document 2000715 details the results of a test where 900 W was applied to the Lower Ring emulating heating from a rocket motor for 188 seconds preceding a separation at 10 Torr Upon subsequent successful separation the temperature difference between the Upper and
96. rcuit shown in Figure 6 10 to measure voltage and current of the Lightband during operations 18 Source PSC Document 2000781E 10 July 2014 www planetarysys com Page 48 of 97 2000785E User s Manual for Mark II Lightband Planetary Systems Corporation Deploy m R H Ohm 0 1 EHE Bain _ lt gt m 6 B NC 7 C g Switch stote shown ot EN beginning of operation 9 ooco ococmaecgotnmczdo AV Vp V a 5ft Cable DB9 Interface Lightband PSC Test Rack AV Ib A Figure 6 10 Electrical schematic of circuit used to measure current and voltage of Lightband 6 7 Separation Parameter Variation The following figures are used to illustrate how a Lightband s time to initiate varies with both voltage and temperature Voltage vs Time to Initiate w a Single Motor Voltage V Time to Initiate sec Figure 6 11 Voltage vs time to initiate at various temperatures with a single Motor only at S10 Torr 19 Source PSC Documents 2002305 2001044 and 2000715 10 July 2014 www planetarysys com Page 49 of 97 2000785E User s Manual for Mark II Lightband Planetary Systems Corporation Voltage vs Time to Initiate w Both Motors e O o 0 30 0 40 0 50 0 60 0 70 Time to Initiate sec Figure 6 12 Voltage vs time to initiate at all temperatures with both motors at 10 Torr 10 July 2014 www planetarysys c
97. re values Though somewhat subjective if adjoining structures are relatively stiff the required flatness will be greater than if the adjoining structure is relatively flexible A relatively flexible structure will conform to the flat interface better than a relatively stiff one See Figure 5 18 If in doubt about the stiffness of your adjoining structure please contact PSC Stiff Flexible No moment arm from web to bolt hole Moment arm from web to bolt hole Bolt holes aligned with structure Bolt holes not aligned with structure Thick walls relative to bolt diameter Thin walls relative to bolt diameter Figure 5 18 Example of stiff and flexible adjoining structures 10 July 2014 www planetarysys com Page 24 of 97 2000785E User s Manual for Mark II Lightband Planetary Systems Corporation The type of adjoining structure can also have an effect on operation and integration of the Lightband Customers should be aware of the effects of their choice of adjoining structure before integration and adequately plan for any likely issues See Table 5 5 EE Lightband Adjoined to FT Stiff Weldment Ring or Plate Transition Rings Isolation System Typically Characterized As See Table 5 1 Stiff Flexible Flexible Most Similar Type of Flight Adjoining Structure Characteristic Adapter cone or ring Isolation system Often difficult to manufacture within Often too stiff does not allow Lightband to maintains required stiffness during Provides
98. res in the structures adjoining the Lightband As the analysis in Table 5 4 shows thick flanges small moment arms and chamfers or large radii create much stiffer and lighter structures Max Deflection Plot Design Notes Deflection Value in e Flanges too thin 0 0050 e Moment arms too large e No chamfer or fillet e Thicker flanges e Smaller moment arms but fits fasteners e Chamfer added for stiffness e No significant increase in mass Table 5 4 Features of adjoining structure The stiffness of the flanges are important relative to overall stack stiffness If the flange stiffness is too low the first mode lateral frequency of the entire stack can decrease detrimentally For proper operation of the Lightband the flanges should be stiff enough to guarantee the preload of the Lightband will not excessively warp the adjoining structure and vice versa PSC offers consultation on design of adjoining structures to customers The lower cylinder represents a Lightband The upper cylinder with flange represents an adjoining structure The applied load is 1 000 Ib The materials are aluminum 10 July 2014 www planetarysys com Page 23 of 97 2000785E User s Manual for Mark II Lightband Planetary Systems Corporation Figure 5 17 Structures with optimal flange design Moment arms in the flange are minimal maximizing stiffness and strength As noted in Table 5 1 there are two sets of required flatness for adjoining structu
99. rysys com Page 92 of 97 2000785E User s Manual for Mark II Lightband Planetary Systems Corporation 25 Storage Requirements Store the Lightband in a sealed enclosure in relative humidity of less than 95 at temperatures between 0 and 50 If possible store the Lightband in the deployed state PSC ships in this state as well The Separation Springs do not creep due to long term storage and the Lightband can remain stowed and ready for separation The shelf life is estimated to be 20 years The most extreme storage environment a Lightband has been exposed to was on the STS 116 and STS 127 missions In those cases six Lightbands were on orbit for more than two weeks after sitting on the launch pad for several months The uncontrolled thermal cycling about 250 cycles from 25 to 70 C at 10 Torr in the shuttle bay is estimated to be an extremely rigorous verification of the Lightband s capacity to operate after long term storage In another example a MkII Lightband on the STP S26 mission remained stowed on orbit for more than 90 days because of a satellite communication issue Upon receiving the 3 month late separation signal from the final stage the Lightband separated nominally 10 July 2014 www planetarysys com Page 93 of 97 2000785E User s Manual for Mark II Lightband Planetary Systems Corporation 26 Procedures Documents and Publications Procedures and Documents 2000867 Lightband Retaining Ring Preload Recommendations Automati
100. spected to verify that it still operates nominally Standard Levels Half of maximum loads shown in Table 5 1 Lateral and axial loads applied independently The load is held at maximum level for at least 60 seconds Load is applied in about 2096 increments Number of separations One 1 following all load cases Criteria for performing test 1 The unit demonstrates an axial line load margin of safety of less than 1 0 and a lateral line load margin of safety of less than 1 0 in pre test analysis OR 2 Theunit design is custom such that it uses materials in the load path that are different from those in Table 5 9 OR 3 The unit will not undergo a random vibration test to verify workmanship Lower Plate is considered fixed and all forces from In line Loads on are calculated in the Test Cylinders act Load Item coordinate system through Hard Points on Upper Plate for F Lifting Test item Coordinate all calculations 1 Origin and Test Fixture J Coordinate Origin are Offset by H2 Test fixture is a regular hexagon with C3 and C6 faces parallel to the X Z plane Test Item Coordinate 7 System Hydraulic 77 Test Fixture Valves and gt Coordinate Pump Cart i J E System V Hydraulic Cylinder Assemblies Rack connecting rod on left hidden for clarity Figure 15 9 The PSC Strength Test Fixture 10 July 2014 www planetarysys com Page 76 of 97 2000
101. stantially reduce testability of the Lightband due to the force 20 0 Ib of each spring 4 Applied independently Ultimate strength is estimated to be 50 higher Cycles at maximum load are discussed in later sections 5 The customer supplied wiring harness typically creates unique stay out zones exceeding these dimensions 6 7 8 9 6 Does not include compliance of the joint to the adjoining structure 7 If in doubt contact PSC See discussion of features on adjoining structures in Section 5 9 8 Measured about CM in stowed state 9 Installing a large quantity of Springs may prohibit the installation of the max quantity of LCTs Table 5 1 Lightband capabilities and dimensions 10 July 2014 www planetarysys com Page 21 of 97 2000785E User s Manual for Mark II Lightband Planetary Systems Corporation 5 6 Tolerance on Dimensions PSC Document 3000233 PSC Tolerance Standards defines all PSC standards regarding measurement tolerance For reference distance tolerances are shown in Table 5 2 O Tolerance unit 0 001 X XXX t 0 005 X XX X 1 000 Table 5 2 PSC distance tolerances 5 7 Stiffness The method used to determine stiffness of the Lightband is shown in the latest revision of PSC Document 2000541 Lightband Stiffness The values are shown in Table 5 1 Higher fidelity stiffness estimations of the Lightband can be determined via FEM
102. sts prior to delivery FEA Finite element analysis Flight Unit A Lightband designated for use as a hardware that will fly into space Flight units are exposed to standard testing prior to delivery FMEA Failure modes and effects analysis GSE Ground support equipment IAW In accordance with Lightband Compression Tool LCT Assemblies used to safely mate the Upper and Lower Rings together MBA Motor Bracket Assembly NBE Narrow bandwidth exceedance Nominal Operation Separation of the Lightband at 23 10 with both motors at 28 4 V Product Build Specification PBS A summary document of requirements for testing and subsystem configuration springs switches connectors SCC Stress corrosion cracking Set for flight Moving the Ball Nut from the stow endplate to the deploy end plate This relatively low power operation significantly decreases the time to initiate by reducing the distance the Ball Nut needs to travel to initiate SRS Shock response spectrum Stow To join the Lightband by operating the motors until a stow Limit Switch opens a circuit Test Readiness Review TRR Verify test plans meet PBS Time to initiate Power on until any deploy Limit Switches first opens a circuit Time to deploy or separate Power on until a loop back in a Separation Connector opens a circuit This corresponds to about 0 130 inches of travel in the direction Test Complete Review TCR After each test the meeting that is held to review
103. style to match latest PSC standards Added discussion of Lightband Training Course in multiple locations Modified table and figure caption scheme Many editorial edits 02 Apr 13 AZ WH Added Section 8 2 Added Footnote 14 16 and 17 to cite source of nominal operation profiles Corrected Equation 5 first m changed to n Normalized data in Table 5 3 Data disclaimer added in Section 5 8 Corrected Equation 2 Added Figure 5 18 Modified Table 5 1 to include flatness for both stiff and flexible structures Corrected Equation 7 Corrected caption in Table 6 3 10 July 2014 www planetarysys com Page 4 of 97 2000785E User s Manual for Mark II Lightband 10 July 2014 10 Jul 14 Planetary Systems Corporation Removed flight heritage Table 4 1 and replaced with a reference to PSC s website Added Section 16 regarding previous qualification testing Added Table 5 5 to Section 5 9 Updated Figure 15 8 Figure 2 1 Updated Figure 2 10 Added Figure 2 11 Updated Section 4 Updated flight history quantity Table 5 1 Added row for max qty of LCTs edited row title for max sum of Connectors Switches and Roll Brackets Figure 5 2 Updated with better image quality graphic Figure 5 7 Updated with better image quality graphic Table 5 9 Updated and marked some part numbers proprietary Table 5 10 Added Lightband Compression Tool Assembly Section 5 10 Changed specified torque value clarified torque exceedan
104. ta evan de Ere deve o ceu aude vou de oe va ees evan a ce dover eee 69 15 1 STANDARD AGCEP TANCE WES ES feta ette po CAU AUS etel E E Arca E cf IS 70 10 July 2014 www planetarysys com Page 2 of 97 2000785E User s Manual for Mark II Lightband Planetary Systems Corporation 15 1 1 Vibration mcr NE LE UR i MILD IM LIE MIHI MM LRL EL MM ce 70 15 1 2 m E RERO RERO RR heal reat So tanec hee PIU SCR 72 1543 DESL E t Oe 7 15 2 OPTIONAL ACCEPTANGE TESTS jose osten Fri eo osea issus t sata ase 76 USA neu 76 15 2 2 SPIO DNONNKP PO M J 77 16 QUALIFICATION TESTING OF 5 79 16 1 VIBRA ON OAT ON Ue S A 79 16 1 1 MLB15 000 Vibration Qualification 65b oer ete etc eee See even Deed aceto ves pee 79 16 1 2 MLB38 810 Vibration Qualification
105. the Lightband s fatigue life will be consumed omen ASD G Hz Le or AREA Ome 0 0260 0 1600 01600 oo 400 oo i225 no 0 0260 199 82 1414 Table 16 3 Previous qualification test vibration limits of MLB38 810 Parameter Value Tolerance Overall Grms 14 14 Duration per axis min 10 0 Axes tested X Y Z Ctrl tolerance dB bL LL LL Lbbo o Lo Lo bob bd Lo CHES ESCH TTT ll pi oe BE i S p _ 1 M Frequency Hz N I 9 10 o lt HA Figure 16 2 Random vibration profile of qualification test of MLB38 810 10 July 2014 www planetarysys com Page 80 of 97 2000785E User s Manual for Mark II Lightband Planetary Systems Corporation 16 2 Thermal Vacuum Qualification Test Tested thermal vacuum limits of a 15 inch diameter Lightband are shown in Table 16 5 The Lightband operated nominally after completion of test Thermal Cycle Max Pressure Dwell Time at Ctrl Temp High Temp Temp No of Thermal excluding Bake Low Temp Tolerance C Cycles High amp Low Sensor out Torr y Temp min Location 1 00E 04 111 0 Table 16 5 Previously tested thermal vacuum limits of MLB15 000 16 3 Strength
106. the current into the motors is monitored during this operation as shown in Figure 6 10 it will provide data to clearly indicate the capacity of the Lightband to operate properly on orbit Maximum reliability of the Lightband can be attained by minimizing the power conducted into the Lightband and the number of cycles Specifically avoid unnecessary stow deploy operations and minimize applied voltage levels as higher voltages will put more power into the mechanism More power eventually leads to higher stresses applied to the Motor Bracket assembly PSC constantly advances the Lightband technology to increase reliability during ground test and in flight By building and testing about 15 flight Lightbands per year PSC engineers are made aware of trends that may compromise reliability 10 July 2014 www planetarysys com Page 64 of 97 2000785E User s Manual for Mark II Lightband Planetary Systems Corporation 12 Failure Modes and Effects Analysis FMEA PSC Document 2000770A Motorized Lightband Failure Modes and Effects Analysis provides a detailed FMEA The FMEA has four major sections Primary Load Path Motor Bracket Assembly Subsystems and Human Error The most likely source of failure has been customer user error A customer bypassed the Limit Switches turned off current limit and then used a screw driver to help the Lightband stow It was already stowed which is what the Limit Switches were for e A customer forgot to not
107. the last of three axes of vibration WARNING These vibration levels should not be applied to the Lightband when the Lightband is supporting a substantial mass without carefully considering the effects of resonance and structural impedance The prescribed environment below is for the Lightband alone When the Lightband is supporting a structure engineers must determine how the vibration environment will generate line loading and how much of the Lightband s fatigue life will be consumed Freg Hz ASD GUHz OCT Slope dBJOCT AREA Gm po c r 00800 789 132 60 125 11 0080 000 400 00 625 78 00130 789 132 60 9991 Table 15 2 Nominal acceptance random vibration test profile Parameter Value Tolerance 60o 1006 po estosted _ XYZ __ Ctrltolerance 10 000Hz dBB o o OWoelrane 1000Hz dB 30 NBETol20 100 Hz 10 Data Sampling Rate Hz Table 15 3 Nominal random vibration test parameters 3 0 Max Ctrl Bandwidth Hz 10 10 July 2014 www planetarysys com Page 70 of 97 2000785E User s Manual for Mark II Lightband Planetary Systems Corporation 1 00 e i e ASD G2 Hz 0 01 Pt tit 1 lid A et Frequency Hz Figure 15 2 Nominal acceptance random vibration test profile Figure 15 3 Nominal vibration test configuration ML
108. to separate on orbit To date the Lightband has operated successfully in flight more than 40 times See the flight heritage section of PSC s website for the most up to date list http www planetarysystemscorp com Planetary Systems Corporation Figure 4 1 A Lightband installed on TacSat 2 10 July 2014 www planetarysys com Page 12 of 97 2000785E User s Manual for Mark II Lightband Planetary Systems Corporation 5 Mechanical Properties 5 1 Lightband Description The coordinate system for the Lightband is shown below It is a right hand coordinate system The Xig axis originates from the Lower Ring bottom plane and points towards the Upper Ring The Y s axis passes through the center plane of the Motor Assembly The Lightband Upper and Lower Rings are engraved with Yi amp and 4 during manufacture Unless otherwise noted all axes in this document refer to the Lightband coordinate system and all dimensions are given in inches Upper Ring Mounting Hole 50 28 thru 0 50 on opposite side 24x on 215 000 BC Upper Ring Retaining Ring Leaf Retaining Cord Xig Lower Ring Mounting Hole Z LB 50 28 thru 1 0 50 24x on 015 000 BC Separation sj lt Switch 1 7 e Motor Bracket Assembly Lower Ring Lightband Operation Electrical Interface Hinged Leaf Assembly DB 9 Socket Connector Separation Spring Figure 5 2 The Leaves beginning to disengage during deployment Retaining Ring removed
109. uctural fasteners of primary load path state Deploy 3 Deploy 6 May be placed on upper and lower ring Metal housing is an option Motor B NO 7 Metal plungers are not reliable means to assure electrical continuity from Upper to Lower ring Stow 7 Lightband Lower Ring 8 DB9 Socket Typically on Launch Vehicle Lightband Lower Ring Typically on Launch Vehicle Figure 6 1 Lightband Schematic 12 The DB 9 connector and the Motor cases are electrically grounded to the Lower Ring 10 July 2014 www planetarysys com Page 41 of 97 2000785E User s Manual for Mark II Lightband Planetary Systems Corporation gt STOWING 2 3 4 3 0 2 5 2 0 1 5 1 0 27 5 1 0 5 15 5 0 5 1 Voltage V y 0 5 0 0 Current Motor A Current Motor B y 7 0 5 Voltage Motor A 40 ix Voltage Motor B T Circuit tao STOW the DEPLOYED Switch 0 00 0 20 0 40 0 80 0 80 1 00 1 30 i Circuit to SET FOR STOWE D Switch state Lightband state prior to stowing Ti FLIGHT the Lightband prior ta SET FOR operation ime sec FLIGHT operation Notes See latest revision of PSC document 2000781 MLB Operating Procedure for best voltages Larger DEPLOYING 2 Lightbands generally require higher stowing voltages SETTING FOR FLIGHT 2 2 Only operate the Lightband if operator has passed FSC s training course Current Motor A
110. ue ceo eere ederet eee LU DE n eR DE e e M 54 8 L IGHTBAND SHO GR Det rc tee tet sheen A ce et cee oh on S 55 8 1 MAXIMUM SHOCK FROM THE BIGEHTBAND S gt EN OC heh tr cel A Pat OL hh gtr ete oa ele 55 8 2 MAXIMUM SHOCK APPLIED TO THE LIGHTBAND 58 9 SELECTING A LIGHT BAND 2030 L 59 10 OPERATING THE EIGHTBAND i ci obedece eene ee eet ehe optatae coste ees lee es relat ote oma E 62 10 1 ABOGBSSTOTPASTENEBHSSLDIM ILI ARM Dp 62 10 2 VERTICAL AND HORIZONTAL INTEGRATION TO ADJOINING VEHICLES ccececececececececececececeaeaeaeaeacueuceeucueeeeceeeceneneneaeaeaeaeaeavavatanaeeeeeenenes 62 11 2550524020 10h 6224 Sle Barb Solon oS Data bor D DOM DA Ma aca 64 12 FAILURE MODES AND EFFECTS ANALYSIS FMEA 5 22x enia sur uu ap ku RENS EE 65 13 CLEANLINESS g HAN DLN ICE O O O O H 66 14 MANUFACTURING PHOCESS 4t RE ER Eee rime recente Exe oe eei I EDI EPIRI 67 15 ACCEPTANCE TESTING OF LIGHTBANDS ne owe o
111. uly 2014 www planetarysys com Page 66 of 97 2000785E User s Manual for Mark II Lightband Planetary Systems Corporation 14 Manufacturing Process Engineers at PSC design assemble and test Lightbands All of the machining and fabrication is completed by vendors qualified to PSC s standards PSC maintains written documentation of all tasks associated with flight hardware procurement storage assembly test and shipment Lightbands and their subsystems are tracked and completely traceable using their purchase order serial number or lot number Just like in testing at PSC manufacturing is done in teams Two engineers sign off on steps in manufacturing procedures one acts as the technician the other as quality assurance and three engineers execute a Build Complete Review BCR as the final step in the completion of the manufacturing procedures PSC writes executes and approves manufacturing procedures PSC also takes any corrective action after required customer notification if anomalies arise The customer furnished wiring harness is not included in the manufacturing of a Lightband at PSC The harness is added later by the customer Step 2 PSC s Standard Execution Procurement and Assembly Anomaly Reporting and Disposition Documentation and inspection of parts procedures and Any non compliance assembly This includes bench top separation 5 BCR Verify product assembly y for test Test Readiness Review TRR Verify test plans meet P

2000785 Rev D User`s Manual for Mark II Lightband

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