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2000785 Rev D User`s Manual for Mark II Lightband

1. 46 7 13 Nd IRA CNN sat ste RECTOREM 46 8 5 47 VALUE OF MOTORS IN EXFREME THERMAL ENVIRONMENTS sien Bez undue eue tuendo senis rn 47 8 amp 2 SURVIVAL AND OP RATING ethan alee i 47 8 3 JAXBSORHPTIVITYAANBEEMISSIVITM toco dun I Let bee cer Saket ats ERE LL ML cts et E DLE E SLE 47 8 4 RESISTANGE PORTER NEIUREE 47 8 5 JNOMINAL THERMAL RESPONSE 2 2 5 53 rv est vero facto Peto Pes elt Seve died etl aedi ess aes 48 8 6 THERMAL GRADIENTS AND TRANSIENTS cccccececececcecececcceccecececucauaeauaesecsuauauaesecsecuausesecauauaunenecseataeauaenenersuauaunetscaeauaenenensteuaenensnensnenenaenes 48 9 SHOCK IPROPERTIES TR 49 9 1 MAXIMUM SHOCK GENERATED BY EIGHTBAND i cen ende ied de fca reas 49 92 MAXIMUM SHOCK APPLIED TO EIGBTBAND 5 bea ec em eb e rrara Ob ae eee On ue abe erecto bodies 52 10 wia B Pi n Deest Ser Ttt ST 53 11 FAILURE MODES AND EFFECTS ANA
2. 87 28 A 88 30 July 2014 www planetarysys com Page 3 of 88 2000785F MkII MLB User Manual Planetary Systems Corporation 1 Revision History Written Released Previous revision change logs recorded on file for document simplicity 02 Apr 13 AZ WH e Added Section 9 2 e Added footnotes to cite source of nominal operation profiles e Corrected Equation 5 first changed to Normalized data in Table 6 2 Data disclaimer added in Section 6 7 Corrected Equation 2 Added Figure 6 18 Modified Table 5 1 to include flatness for both stiff and flexible structures Corrected Equation 8 Corrected caption in Table 6 3 Removed flight heritage Table 4 1 and replaced with a reference to PSC s website Added Section 19 regarding previous qualification testing Added Table 6 4 to Section 6 8 Updated Figure 18 9 E 10 Jul 14 AZ WH Figure 2 1 Updated Figure 2 8 Added 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 6 5 Updated with better image quality graphic Figure 6 10 Updated with better image quality graphic Table 6 8 Updated and marked some part numbers proprietary Table 6 9 Added Lightband Compression Tool Assembly Section 6 9 Changed specified torque value clarified torque exceedances Section 6 9 Added discussion of reduced head diameter fa
3. 33 6 19 E MUR EE M MD S Men sn MM ML E E 33 6 20 COMPONENT SPRING PARAMETERS a a e A eee 34 6 21 ROTATION RATES SEPARATION VELOCITY AND SEPARATION SPRINGS 35 7 ELECTRICAL PROPER TE RENE a a tebe ee eta eee 38 TA EE e ru og O ceaseless ees EE AE OEE EE EEE 38 72 THE MOTOR BRAGCKET ASSEMBLY x Aa ONE a A AE 39 7 3 WIRING HARNESS DESIGN aes erede ic real rn aceite eee mace eet asec Ru ass LE red A E 40 7 4 SEPARATION ELECTRICAL rc erue haee e de ee ne o e eer e rade aee do tee teneo en eios 41 A SEPARATION SWITCHE S eee CAM DE UE C EA 42 6 OPERATION ELECTRICAL PARAMETERS idi ote esu ues esc Me aD Lu s rn t ues DNA DT Eu NL 43 LI SEPARATION PARAMETER VARIATION ode science eeu Eve VOR VOY PR PR DRE SEP CE 44 age TCG CO E MO OA M M M M ML MM UE EIE 45 129 ee Oe ee Ee ee E 45 7 10 mE EARS IG Ge ROUEN ORO MO Se EN 46 7 11 SWAPAGE CHARGING cece cheetah 46 7 12 RADIATION SENSITIVITY
4. 79 19 4 SHOCK QUALIFICATION TEST s Da Pre pev ER rex E bebe exe prr Sere bao vv ou pL ret xs er uer 80 20 LIGHIBAND INSPECTION 22 22 5 5 20 22 522 0 5 30 5 6 00 Eae Eo EQ Coe E eo e DOR oco ed Uo Ee DOS ea oec 81 21 LIGHTBAND TESTING AND PROCEDURES PERFORMED BY CUSTOMER 82 22 GROUND SUPPORT EQUIPMENT CR RR studs EF ER ER Nx ar YR CR SEX ERR S XE SEEN ER ESKRRCRREN CRGA oir 83 23 LIGHT BAND TRAINING ITEM 85 24 PACKING SHIPPING AND UNPACKING METHODS 86 25 PROCEDURES DOCUMENTS AND PUBLICATIONS cccccscccsesceeeceeeeseeeeeeeeueneeeeeeeeeeneueuseeueeeaeeeneeeueeeueeeusenuseusenaseeueneueceeeueusuesenes 87 26 NVI Wc eect caren pci 87 27 ACKNOWLEDGEMENTS
5. MLB User Manual Planetary Systems Corporation all Shear Pin Spring Plunger 3x per Leaf 1x per Leaf Sliding Tube in Deployed Position Hinged Leaf Assembly Figure 6 6 A 15 inch diameter Lightband shown deployed 30 July 2014 www planetarysys com Page 16 of 88 2000785F MLB User Manual Planetary Systems Corporation 6 4 How the Lightband Works Videos showing the Lightband operating on the ground and on orbit are available at www planetarysystemscorp com Figure 6 7 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 hA Figure 6 7 The Lightband in the stowed state top view Figure 6 8 shows the Lightband in the initiated state Upon deployment initiation the motors are powered causing the mechanism to snap inward in approximately 0 065 seconds allowing the Retaining Ring to contract Retracted deployed MS ac NC uu rt L a Figure 6 8 The Lightband in the initiated state 30 July 2014 www planetarysys com Page 17 of 88 2000785F MLB User Manual Planetary Systems Corporation The Leaf Retaining Cord provides a constant radial force inward that causes all the Leaves to bear upon the Retaining Ring After the motors have been initiated the Retaining Ring no
6. 15 1 5 Select a Lightband diameter Choose an appropriate Lightband diameter from Table 5 1 based on stiffness strength cyclic loading and fatigue requirements 15 1 6 Determine payload and final stage masses Payload and final stage masses are necessary to predict flight separation velocity based on tested separation velocity 15 1 7 Determine separation velocity requirement Determine the separation velocity that the Lightband must impart to the payload If no separation velocity requirement exists PSC defaults to a separation velocity requirement of 1 00 0 25 feet per second Separation velocity is of course driven by payload and final stage masses Any separation velocity that requires more or fewer Separation Springs than shown as allowable in Table 5 1 shall be considered a Custom Lightband If a Custom Lightband is not desired PSC will default to the closest Separating Spring quantity allowable in in Table 5 1 The standard separation velocity tolerance is 25 Section 6 21 details how to calculate the estimated spring quantity 30 July 2014 www planetarysys com Page 60 of 88 2000785F MkII MLB User Manual Planetary Systems Corporation 15 1 8 Determine Separation Switch quantity The greater the quantity of Separation Switches the more complex and heavy the harness By default PSC can include two Separation Switches in the price of every Lightband If more than two Separation Switches are required an additional cost is typically inc
7. At a minimum the following topics will be covered during the training session 30 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 Preparing the Lightband for compression Removal from adjoining structure procedure Horizontal integration procedure if applicable Lightband Compression Tool 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 85 of 88 2000785F MLB User Manual Planetary Systems Corporation 24 Packing Shipping and Unpacking Methods PSC Document 2000827 MkII MLB Pack Unpack Procedure defines the methods to pack and unpack the Lightband from its shipping container Description The Lightband is shipped in the deployed state with the Motor Bracket Assembly in the stowed position to constrain motion during shipping Red non flight stand offs are used to hold the Upper and Lower Ring separated The Lightband is prepared for shipment Typically each Lightband is shipped in custom designed protective case dedicated for that particular unit The case is reusable The Lightband is bagged and sealed Composite foam shapes encapsulate the Lightband inside its case The
8. Voltage Mtr Voltage Mtr B 25 25 0 Current Mtr A Current Mtr B 20 0 Data sampled at 5 000S sec 20 Deploy w single Motor at cold temperature extreme g 150 15 E 6 gt 10 0 Laio 50 0 5 0 0 4 0 0 5 0 4 05 0 00 0 05 0 10 0 15 0 20 0 25 0 30 0 35 040 Time sec Figure 7 9 Only Motor A is powered and thus Motor B indicates a voltage but not a current 7 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 7 10 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 21 8 21 6 21 4 47 5 21 2 47 C Shorted 5 21 0 mE 23 Shorted 102 102 Shorted 20 6 20 4 20 2 0 0 0 2 0 4 0 6 0 8 1 0 Time to Initiate sec Figure 7 10 Voltage vs time to initiate at various temperatures with a single Motor or a single shorted Motor at 310 Torr 17 Source PSC Document 2002305 30 July 2014 www planetarysys com Page 45 of 88 2000785F MLB User Manual Planetary Systems Corporation 7 10 Electrical Resistance The resistance from the upper surface of the Upper Ring to the l
9. MLB Diameter iot Separating Tol Ib Mass Tol Ib Ib in Ib in Ib in Ib in 8 000 5 363 25 396 11 732 5 457 26 134 15 000 10 355 25 305 Table 18 3 Standard Separation Reliability Separating Mass CGx amp moment of inertia values 19 848 39 604 76 992 99 112 30 July 2014 www planetarysys com Page 70 of 88 2000785F MLB User Manual Planetary Systems Corporation Separation Reliability Testing Source Document s PSC Document 2000785 MLB User Manual Test Objective Demonstrate that the test item separates reliably Test Complete Criteria 1 The test item meets all requirements defined in the test plan over 10 consecutive separations 2 The test item is inspected IAW PSC Document 2001066 MLB Inspection Report upon completion of test 3 All attendees of the PSC internal Test Complete Review TCR approve the test plan and results Notes 1 Test fixture limitations can affect attainable inertia values Tolerances will be specified on a best effort basis 2 Dependent on test SV mass Ensure minimum Flight Delta V requirement will be met 3 Spring energy J 1 020 4 Spring efficiency 0 9 Test Parameters Parameter Test Config Test Tolerance Payload SC Mass lb See Table 18 3 See Table 18 3 Final Stage FS Mass lb 1 00E 06 Remark FS simulated by stiff static fixture Requirement See Table 18 3 See Table 18 3 See Table
10. Minimum Maximum E E Operating Limit 54 Ideal Operating Temperature 35 Table 8 1 Survival and operating temperature limits 8 Extensive testing has shown the ideal operating temperature is 35 C This temperature minimizes time and energy required to initiate At lower temperatures the energy and time to initiate increase because of the greater viscosity of lubricants and CTE mismatches of the components As such cold temperatures 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 8 3 Absorptivity and Emissivity The materials in Table 6 8 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 dependent upon variations in surface finish For the clear hard anodize of the Lightband Upper Ring PSC defers to industry accepted range for these values given in multiple sources Lightband Characteristic Solar Absorptivity a 0 27 to 0 35 Emissivity 0 76 to 0 84 Table 8 2 Lightband absorptivity and emissivity ranges Customers have occasionally inquired about the possibility of black anodizin
11. Motorized Lightband Failure Modes and Effects Analysis provides a detailed Lightband FMEA The FMEA has four major sections Primary Load Path Motor Bracket Assembly Subsystems and Human Error The most common source of Lightband failure has been customer user error because they neglected to read the operating procedure and receive training Here are a few examples A customer disregarded the operating procedure bypassed the Limit Switches turned off the power supply s current limit and then used a screw driver to help the Lightband stow It was already stowed which led to irreparable damage Figure 11 1 End plate ripped off Sliding Tube because the Lightband was not properly operated customer forgot to force limit vibration inputs while performing a random vibration test and cracked a Lightband Leaf then continued the test without noticing the cracked Leaf Figure 11 2 A Leaf from a Lightband cracked in half during a flawed random vibration test e Acustomer had PSC engineers fly to Kodiak Alaska to fix what was thought to be 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 separated cantilevered structure damaged the Lightband A customer miswired the cable from the launch vehicle to the Light
12. TE ce aie eee ne Dueck deen tot oie edn bed 15 6 4 HOW THE LIGHTBAND WORKS Ee rese ee SSE E I 17 6 5 HOW THE MOTOR BRACKET ASSEMBLY WORKS RM MIR nares ae PIA ranra rran DR LA n DP MM E De E IR Rn 19 dm S ROM RECETTE HERR CHROME 21 67 EDU Dx cx e 21 6 8 DISCUSSION OF FEATURES ADJOINING STRUCTURES cccccscececcececscaccucececucucauacauausecsensaueusecscueauausecscueauausesseuseeusatausesseutauausenseusanaeaes 21 69 FASTENERS TOJADJOINING STRUCT URES cea as pee desde iae dvo cda qvos he eee hae egets dt reb 24 6 10 LINE LOAD IMIS NONIS 25 6 11 FLATNESS AND PARALLELISM 2 cias eeu eoa nants uc ed 27 6 12 alee gt et OEY MM A PRT Net PT 28 6 13 SO Teak NE TIE e tet 29 6 14 FR TOU eh RP 30 6 15 SCREFURBISHMEN TTE 31 6 16 de eMe ad tad eM adn A dehy Dia Oph ird hatte d kei ghd 31 6 17 MATERIALS AND SUREAGE TRE ATMIEN 32 6 18
13. s testing of the Lightband does not include the customer s 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 Prior to these tests PSC completes several bench top separation operations in order to tune in the preload force of the Retaining Ring There is no fixed sequence for these tests Generally customers are permitted to send one person to attend all testing at PSC Arrangements must be made with PSC in advance if a customer representative is to attend a test Standard or Typical Number of Custom Separations Performed Bench top separation Standard MEME Vibration Test Standard Thermal Vacuum Test Standard Strength Test Custom Shock Test Custom uU Total excluding custom tests 12 17 Table 18 1 Standard test operations summary Separation Reliability Test Standard 18 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 18 1 1 Random Vibration Test
14. separation velocity Typically one spring plunger is used per Leaf Assembly Data for mated 0 01 pair Each total of connector has 15 all pins spring plunger contacts Separation Connector Each Switch houses one spring plunger Separation Switch Table 6 10 Spring parameters Source PSC document 2001071 Monte Carlo analysis 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 30 July 2014 www planetarysys com Page 34 of 88 2000785F MLB User Manual Planetary Systems Corporation 6 21 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 For standard Lightbands the nominal rotation rate requirement 1 0 0 1 0 degree 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 Equation 4 assumes the adjoining vehicle is many times more massive gt 10X and has many times more inerti
15. 181 0 M kg 300 0 T E gt L 2 gt 8 10 12 14 16 18 20 22 S Quantity of Sep Springs Figure 6 32 Spring quantity required increases with the square of velocity The location of Separation Springs Connectors and Switches need not be symmetric to minimize rotation rates Sometimes PSC engineers will modify 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 18 1 3 This testing is performed on all flight Lightbands When several payloads are on the same launch vehicle engineers can minimize the possibility of re contact by varying the separation velocity and direction Angling the payloads so they push through the center of mass reduces rotation rate torques and the possibility of re contact See Figure 6 33 Figure 6 33 Simulated view of several payloads on the same launch vehicle 30 July 2014 www planetarysys com Page 37 of 88 2000785F MLB User Manual Planetary Systems Corporation T Electrical Properties 7 1 Schematics Lightband after deployment Lightband is separated Lightband Upper Ring Typically on Space Vehicle Lightband ready for flight Lightband Upper Ring Typically on Space Vehicle Separation Switch es 6 indicate separation tu
16. EPUM ics ConmoSmagy Max HL E Cf Cp 9 qw 0 29 Source PSC Document 2002080 30 July 2014 www planetarysys com Page 78 of 88 2000785F MLB User Manual Planetary Systems Corporation 19 2 Thermal Vacuum Qualification Test Tested thermal vacuum parameters of a 15 inch diameter Lightband are shown in Figure 19 2 Qualification Thermal Vacuum Testing Source Document s Document 2002305 Test Objective Demonstrate that the test item operates nominally after thermal and pressure cycling Test Complete Criteria 1 The test item deploys nominally at each designated step 2 The test item is inspected IAW PSC Document 2001066 MLB Inspection Report upon completion of thermal vacuum cycling 3 All attendees of the PSC internal Test Complete Review TCR approve the test plan and results Notes 1 In a separation springs travel at least 0 7 inches in an initiation springs travel 0 0 inches 2 PSC does not guarantee pressure will remain below 1 0E 4 Torr at temperatures above 23 C for first several cycles 3 A bake out occurs after chamber is closed Max bake out temp shall be whichever is greater required high temp or 70 C Thermal Cycle Bake out 3 Tem Temp No of Dwell Time at Ctrl Temp Duration excluding Bake 9 E Low Temp Tolerance Thermal High amp Low Sensor Temp C min out Torr 2 Cycles Temp
17. 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 Figure 18 2 defines 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 TR 06 1 1 Number of separations One 1 following the last of three axes of vibration WARNING These vibration levels shall 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 Figure 18 1 Nominal vibration test configuration MLB15 000 shown 30 July 2014 www planetarysys com Page 66 of 88 2000785F MkII MLB User Manual Planetary Systems Corporation Random Vibration Testing Source Document s Test Objective Demonstrate that the test item operates nominally after vibration loading Test Complete Criteria 1 The required
18. cycle the Lightband must be inspected by PSC Engineers to determine the wear rate and the amount of lubrication remaining Using the minimum allowable voltages on all operations maximizes the Lightband s cycle life Lower voltages produce lower currents meaning 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 After a Lightband has been cycled 60 times it must be inspected by PSC and considered for refurbishment The typical refurbishment process is as follows 1 Lightband is shipped to PSC 2 Provenance of the Lightband is established What handling operation testing occurred while outside PSC 3 Analysis of handling and testing is performed to establish potential risks and problem areas For instance what line loading was experienced in test 4 Lightband is inspected based on Step results This could be as simple as a visual examination or a complete tear down assessment Only known non destructive inspection techniques like dye penetrant analysis are performed 5 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 6 Therefurbishment plan is executed 7 Abenchtop and environmental
19. 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 Figure 18 15 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 flight Lightband 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 Shock Testing Source Document s PSC Document2000785 Test Objective Measure the maximum shock that the test item produces Demonstrate that the test item operates nominally after exposed to shock loads Test complete criteria 1 The required shock profiles are applied to the test item in the specified axes 2 Shock produced by the test item is measured 3 The test item separates nominally after being exposed to required shock profiles 4 The test item is inspected IAW PSC Document 2001066 MLB Inspection Report upon completion of shock exposure 5 All attendees of the PSC internal Test Complete Review TCR approve the test plan and results Notes 1 In a separation springs travel at least 0 7 inches in an initiation springs travel 0 0 inches 2 Test Spectrum must also be 5096 above the Nominal SRS 3 Upper tolerance is a guideline not a requ
20. 1 04 1 12 1 14 1 14 1 10 0 98 0 95 0 00 0 00 0 00 0 00 0 00 0 00 0 00 0 00 0 00 0 00 Center of Mass Ai Upper Assembly 0 1 in 3 Yip Upper Assembly 1 120 9 1 266 7 3 051 9 5 622 2 508 1 577 6 1 423 9 2 648 4 619 4 696 1 1 637 1 2 985 1 1 720 6 866 3 855 5 21 Upper Assembly a X Lower Assembly 0 88 0 85 0 85 0 86 0 85 0 84 0 84 0 84 0 86 0 85 E Yig Lower Assembly 1 19 1 44 1 41 1 37 1 51 1 58 1 60 1 52 1 44 1 39 0 Zp Lower Assembl 0 00 0 00 0 00 0 00 0 00 0 00 0 00 0 00 0 00 0 00 gt Inertia 10 Upper Assembly Ib in 3 Upper Assembly 177 Upper Assembly ho Lower Assembly Lower Assembly Izz Lower Assembl X axis Ib or ZB axis Ib 26 320 26 320 30 080 33 840 45 120 56 400 5 418 5 418 6 192 6 966 9 288 11 610 Moment about Y or Ze in Ib 120 085 130 600 174 840 203 040 356 448 547 221 Maxium Loads S eo Stiffness about X 25 Ib in 6 Stiffness about Y g or Zg 25 in lb rad 6 8 73E 06 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 0 0021 0 0031 0 0035 0 0040 0 0049 0 0053 0 0062 0 0064 0 0084 0 0103 24 32V for 24 32V for 24 32V for 24 32V for 24 32V for 24 32V for 24 32V for 24 32V for 24 32V for 24 32V for 0 5s 0 5s 0 5s 0 5s 0 5s 0 5s 0 5s 0 5s 0 5s 0 5s 0 065 0 065 0 065 0 065 0 065 0
21. 2030 2 502 0092 0794 0546 0 308 1 546 957 0 482 1582 Comments Mean 1 For acceptance trials only Minimum 2 Assumes the following masses Ib Maximum 3 Time from power on until either deploy limit switch Y Allowable Maximum 4 Sep Arm inertia about CM aligned with MLB coords Roll X Allowable Minimum Figure 18 9 Example test results from separation reliability test conducted on a standard MLB15 000 30 July 2014 www planetarysys com Page 72 of 88 2000785F MkII MLB User Manual Test Inputs Payload SV mass Final Stage FS mass Required AV Determine aty of Sep Springs needed to meet AV requirement via analysis amp install on Lightband Planetary Systems Corporation 3 Select Standardized Separating Arm Configuration Quantity and location of weights are determined in a Solidworks CAD model to meet mass CM and inertia requirements During Test Verify Configuration Build and balance the separating arm LAW with the CAD model Measure weight v via fixture load celis During Test Tuning 6 CAD Model Verification Verify that mass matches CAD model predicted value within tolerance If nat correct discrepancy before proceeding During repeated separations modify Sep Spring configuration amp optionally quantity to meet AV and rotation rate requirements as necessary During Test Acceptance Separ the Lig ntband 5 consec
22. Lower Ring Y 15 Lower Ring 2 23 Upper Ring X 23 Upper Ring Y 23 Upper Ring Z 335 Lower Ring X 23 Lower Ring Y 23 Lower Ring Z 31 Upper Ring X 1 Upper Ring Y 31 Upper Ring Z 31Lower Ring X 31l lower Ring Y 31Lower Ring Z Figure 9 3 Nominal shock response time history from the Lightband separation adjoining mass varies 22 Source PSC Document 2002258 amp NASA HDBK 7005 Section 5 3 4 1 3 Source PSC Document 2002258 30 July 2014 www planetarysys com Page 50 of 88 2000785F MLB User Manual Planetary Systems Corporation Shock Response Spectrum Upper Ring 10 000 Resonance due to fixture mode 1 000 100 Acceleration g e LLL 1 100 1 000 10 Frequency Hz Figure 9 4 Nominal shock response spectrum at the Upper Ring interface for an MLB31 600 Note that in Figure 9 4 a fixture mode is present at around 1 700 Hz This mode explains the 5X amplitude resonance Shock Response Spectrum Lower Ring 10 000 11 1 000 100 Acceleration 9 1 22 100 1 000 10 6 YIib Zlb Frequency Hz Figure 9 5 Nominal shock response spectrum at the Lower Ring interface for an MLB31 600 24 Source PSC Document 2002317 25 Source PSC Document 2002317 30 July 2014 www planetarysys com Page 51 of 8
23. Ring of the Lightband Includes mounting hardware See PSC Document 2001025 a Separation 4000106 0 025 See above onnector Separation Spring 4000307 0 032 Includes mounting hardware Separation Switch Includes mounting hardware main body See PSC Document 2002204 Separation Swen The bracket reacts the force of 4000383 0 006 the plunger Includes mounting bracket hardware Roll Bracket Induces rotation about Xia axis Assembly Includes mounting hardware Lightband 0 010 E ell ert pair per Compression Tool 4000637 each not Includes mounting hardware Assembly per pair Does not include tie wrap Table 6 9 Subsystem Weights 30 July 2014 www planetarysys com Page 33 of 88 2000785F MLB User Manual Planetary Systems Corporation 6 20 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 remaining 10 percent of stored energy is converted to heat from the effect of sliding friction during the separation event Spring Stored Constant Energy N mm Used to create the separation Separation velocity Has Spring telescoping features PSC PNs 2001071 and 2001065 These springs push the Leaves out of the Upper Ring They do not Spring influence CCCI Plunger
24. Systems Corporation 7 6 Operation Electrical Parameters Allowable electrical parameters and schematics for all three Lightband operations can be found in the latest version of PSC Document 2000781 Lightband Operating Procedure which is available for download on PSC s website Skipping the set for flight operation and deploying the Lightband from a stowed state is not recommended If the set for flight operation is skipped the Lightband will require approximately 0 65 seconds to initiate Additionally the time to initiate results will be less consistent over multiple deployments without a set for flight operation Further detail is available in PSC Document 2000901 Vibration Qualification Test of Motor Bracket Assembly Motors are not only the means to initiate separation but outstanding transducers that provide great insight into 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 Note Regarding Current Values The first peak current parameter defined in 2000781 occurs when a motor is turned on First peak current is calculated via Equation 7 Ohm s Law where l is the current in amperes V is the voltage in Volts and R is the motor winding resistance in Ohms When the motor is turned on the current rises to V R for
25. User Manual Planetary Systems Corporation o 1 73 2 7 4 EU up DR M ms Figure 6 3 The deployed or separated view The Springs and Switches are shown fully elongated 6 2 Tolerance on Dimensions PSC Document 3000233 PSC Tolerance Standards defines all PSC standards regarding measurement tolerance For reference distance tolerances are shown in Table 6 1 Tolerance unit 0 001 0 005 0 010 o 0010 0 0 0 0 030 Do 5 100 1 000 Table 6 1 PSC distance tolerances Source PSC Document 3000233 30 July 2014 www planetarysys com Page 14 of 88 2000785F MLB User Manual Planetary Systems Corporation 6 3 Lightband Description The coordinate system for the Lightband is shown below The axis originates from the Lower Ring bottom plane and points towards the Upper Ring The axis passes through the center plane of the Motor Assembly The Lightband Upper and Lower Rings are engraved with 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 Retaining Ring DB 9 socket connector electncal interface for Lightband operation Figure 6 5 The Leaves beginning to disengage during deployment Retaining Ring and Leaf Retaining Cord removed section view 30 July 2014 www planetarysys com Page 15 of 88 2000785F
26. a Space fasteners from TN Isolation system ES vehicle Lightband to adjoining vehicles a E Final stage of launch vehicle Remarks Figure 14 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 Section 22 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 22 30 July 2014 www planetarysys com Page 57 of 88 2000785F MkII MLB User Manual 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 Upper 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
27. a minimum to react the expected line loads Figure 6 21 A round separation system and a square satellite can create high line loading 30 July 2014 www planetarysys com Page 26 of 88 2000785F MLB User Manual Planetary Systems Corporation 6 11 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 Figure 6 22 A Lightband attached to a launch vehicle cone and CAD model showing resulting stress peaking that occurs when adjoining two warped surfaces When the adjoining vehicles are extremely warped or surfaces are not parallel an attempt to join the Lightband to both adjoining structures may simply break the Lightband Joining a Lightband to only one adjoining structure will generally not increase stress 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
28. be overloaded at Vehicle level vibration test Verify workmanship and modes resonance Are notching or force limiting methods employed Verify the initiation circuit and power system Ensure Lightband operation procedures are SS from the launch vehicle will properly initiate being followed by using the latest revision of the Lightband Verify adjoining vehicle will PSC Document 2000781 MLB receive the proper signal upon separation Operating Procedure Table 21 1 Testing and other procedures Figure 21 1 Electro mechanical fit check and a separation test with a Lightband 30 July 2014 www planetarysys com Page 82 of 88 2000785F MLB User Manual Planetary Systems Corporation 22 Ground Support Equipment GSE Several pieces of GSE have been useful to customers in the past In the cases noted in Table 22 1 PSC can supply production drawings Generally 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 adjoining struct
29. case is sealed with Lightband and documentation inside The contents are indicated on the outside of the case The default shipping service is FedEx Standard Overnight Shipping weight and size varies by Lightband diameter Customer receives Lightband and unpacks IAW with PSC Document 2000827 MLB Pack Unpack Procedure Table 24 1 Packing shipping and unpacking method 30 July 2014 www planetarysys com Page 86 of 88 2000785F MLB User Manual Planetary Systems Corporation 25 Procedures Documents and Publications Procedures and Documents 2000867 Lightband Retaining Ring Preload Recommendations Automating 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 25 1 Procedures Documents and Publications 26 Warranty The Lightband warranty is defined in PSC Document 1001015 Warranty MLB 27 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 30 July 2014 www planetarysys com Page 87 of 88 2000785F MLB User Manual Planetary Sy
30. determine the correct Lightband size for their mission requirements 15 1 1 Read this manual If you thoroughly understand the Lightband you will be in the best position to avoid costly test failures and program delays 15 1 2 Determine stiffness requirements The biggest driver in Lightband diameter selection should be payload stiffness requirements From dynamic envelope mission requirements determine the required axial and lateral stiffness of the payload stack The minimum Lightband diameter can then be selected from Table 5 1 However it is prudent to choose a Lightband diameter larger than necessary to provide additional stiffness margin at less than an equivalent increase in weight For example a 15 inch diameter Lightband is about 6 6 times stiffer than an 8 inch diameter Lightband but weighs only twice as much See Section 6 6 15 1 3 Determine strength requirements From your expected mission loads on the payload calculate maximum line load via methods in Section 6 10 Verify that mission loads required to attain those line loads are less than maximum Lightband loads shown in Table 5 1 It is not sufficient to only be below maximum line loading it is also necessary to be below maximum loading 15 1 4 Determine cyclic loading and fatigue requirements Determine if the mission vibration environment will cause an exceedance of allowable line loading If so increase the chosen Lightband diameter until allowable line load is not exceeded
31. e 61 15 1 14 Select Fli ghtor Engineernng Development top ae Ut oos E PUE Res de Quee Eo Op ER catenin 61 15 1 15 SDS GIy Re o 7 a a a a a a 61 15 1 16 OETAN ges AEE EAEE AS RM EU iE 61 16 PURCHASING DELIVERABLES amp SCHEDULE cc ccccccccceesceesceeseueeeeeeeeeueeeueeeueeeeeeueueneeeueeeaueeueseueeeuseueeeueeeuseuueenaeeneueneueueesuuseaes 63 16 1 PURCHASING A EIGHPBAND RENTRER 63 16 2 STANDARD DELIVERY SGHEDU LE 25 2 cos 0 09 9 32x duced 63 16 3 EXPEDITED 15 INCH DIAMETER DELIVERY SCHEDLDIEE rein E per eben ropa Deinde era dee cis epa Rd 63 16 4 CUSTOM EIGHTBAND SGHEDDDE iode 63 16 5 EIGHIBANDIDEHVERABUES E Rc iM E REI Ram b a M A A P RM sua E 64 16 6 Berii NDES PIES T TERN R Mn 64 16 7 ASSEMBLY DRAWINGS ERE TTD D MPQ 64 16 8 LIGHTBAND FINITE ELEMENT MODELS pend Deu dedu ges teca peor 64 17 MANUFACTURING PROCESS e cron coitu deo Ee eoo eu Eee eere Sueno or DDR 65 18
32. ft s varies with payload mass 6 0 25 to 2 0 0 25 to 2 0 0 25 to 2 0 0 25 to 2 0 0 25 to 2 0 0 25 to 2 0 0 25 to 2 0 0 25 to 2 0 0 25 to 2 0 0 25 to 2 0 9 5 1 05 1 05 1 1 1 1 1 1 3 el Max Qty of Separation Springs Max Qty of Lightband Comp Tools 8 Max Qty of Sum of Sep Connectors Switches and Roll Brackets 9 Usable Life Before Potential Refurb cycles 5 60 Ss No j ESSI 4 1 6 2 4 Time required to re stow min N Refurbishment Required After a Separation Special tools required N N N N N N N N N 6 37 37 24 34 2 1 o Max Storage Duration Stowed yrs 1 1 4 6 1 1 1 E qe pa EA Max Storage Duration SFF yrs 11 11 6 6 6 10 4 2 2 3 1 1 1 21 15 13 13 3 5 1 9 9 4 4 0 6 2 1 1 1 1 1 1 3 3 Max Storage Duration Deployed yrs 1 3 8 3 NN o NENNEN s 1 The customer supplied wiring harness may exceed these dimensions 2 The use of Roll Bracket Assemblies or high quantity of LCTs may exceed Stayout Diameter A 3 Does not include Separation Springs or Accessories 4 Measured about CM in stowed state 5 Applied independently Values are qualification loads scaled by a factor of 0 5 6 Does not include compliance of the joint to the adj
33. intent of demonstrating reliability Stowing consumes about 10 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 the current into the motors is monitored during this operation as prescribed in PSC Document 2000781 MLB Operating Procedure 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 increases stresses 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 20 30 flight Lightbands per year PSC engineers are made aware of trends that may compromise reliability 27 Source PSC Document 2002675C 30 July 2014 www planetarysys com Page 53 of 88 2000785F MkII MLB User Manual Planetary Systems Corporation 11 Failure Modes and Effects Analysis FMEA PSC Document 2000770A
34. 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 6 9 and Figure 6 10 Li jal 8 J 15 _ 8 yo Ma SS T s A alm tn cAra e a in E in el eal 3 Leaf Retaining Cord oW E JU Figure 6 10 The Leaf Retaining Cord and the spring plungers shown in the stowed state Upper Ring hidden for clarity Figure 6 11 illustrates the Leaves disengaging due to the force from the Spring Plungers allowing the Separation Springs to push the rings apart Figure 6 11 The Lightband shown deploying or separating 30 July 2014 www planetarysys com Page 18 of 88 2000785F MkII MLB User Manual Planetary Systems Corporation 6 5 How the Motor Bracket Assembly Works The Motor Bracket Assembly MBA is the actuator of the Lightband In the MBA two DC brush Motors connect to Bevel Gears Stainless steel Bevel Gears connect to a brass 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 Slid
35. min Location C 120 0 600 Figure 19 2 Previously executed qualification TVac test parameters 30 Max Pressure 19 3 Strength Qualification Test Tested strength parameters of a 15 inch diameter Lightband are shown in Figure 19 3 Qualification Strength Testing Source Document s PSC Document 2002319A Test Objective Demonstrate that the test item operates nominally after quasi static loading Test Complete Criteria 1 The required loads are applied to the test item 2 The test item is inspected IAW PSC Document 2001066 MLB Inspection Report upon completion of all load cases 3 All attendees of the PSC internal Test Complete Review TCR approve the test plan and results 1 Assumes CM and CM are zero RSS of Y and load factors 2 In a separation springs travel at least 0 7 inches in an initiation springs travel 0 0 inches 3 is compression in test item 4 Applied through CM 5 See 2000785 User s Manual for Lightband for criteria to determine if a strength test is required 6 Peak load target is 102 5 to ensure that 100 requirement is reached Load Application Pre test Analysis Load Application 6 Max Line Max Yig or Zig ad Increment Load Case Load lb bolt Line Load Ib bolt Load Case 1 Load Case 2 Shear 1 2 Percentage A Decrement a d 0 900 2 Faslb 900 0 0 Mustin 15780 0 Peak Loa
36. stroke than higher frequency isolation systems 6 14 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 6 28 30 July 2014 www planetarysys com Page 30 of 88 2000785F MLB User Manual Planetary Systems Corporation 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 6 28 Lightband fatigue limits and line loading 6 15 Lifecycle amp Refurbishment The Lightband can be cycled stow set for flight amp deploy 60 times before inspection by PSC is required This includes about 15 20 separation tests that PSC completes prior to shipping to the customer Thus the customer may typically separate the Lightband about 40 45 times Stowing is more strenuous on the Motor Bracket Assembly than deploying The Lightband s Motor Assembly consumes about 20 Joules of energy when stowing while it only consumes about 2 Joules when deploying After the 60
37. 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 6 23 FEM simulates a clamp band separation system via radially inward preload from band tension Warping can result 30 July 2014 www planetarysys com Page 27 of 88 2000785F MLB User Manual Planetary Systems Corporation 0 000 Figure 6 24 A deflection of 0 004 inches at the interface to adjoining structures is created by preload 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 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 20 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 con
38. test the test item shall be exposed to quasi static loading or sine burst loading that is intended to simulate in flight acceleration forces in the set for flight configuration Each combination of loads is known as a load case In some sine burst tests the loads shall be applied independently along each axis Upon completion of all load cases the test item will be separated and then formally inspected to verify that it still operates nominally Standard Levels Half of maximum loads shown in Table 5 1 Lateral and axial loads applied independently For quasi static tests the load is held at maximum level for at least 60 seconds Load is applied in approximately 2096 increments Test Tolerances Lower limit shall be customer minimum customer load requirement or standard level given above Upper limit shall be the maximum capability given in Table 5 1 to account for intra increment peaking Number of separations One 1 following all load cases Criteria for performing test 1 Theunit demonstrates an axial line load margin of safety of less than 1 0 or a lateral line load margin of safety on yield of less than 11 0 in pre test analysis OR 2 The unit design is custom such that it uses materials in the load path that are different from those in Table 6 8 OR 3 The unit will not undergo a random vibration test to verify workmanship Lower Plate is considered fixed and all forces from Cylinders act through Hard Points on Up
39. testing plan for the refurbished unit is determined This could be all none or a selection of the acceptance tests defined in Section 18 of this document 8 The environmental testing plan is executed 9 The Lightband is shipped back to the customer 6 16 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 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 the 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 Oxo re It is estimated that the variation in alignment in the above process is about 0 001 inches in 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 acco
40. which operate inside these vehicles 8 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 Lower Ring of the Lightband was 30 C Lightband Thermal Transient Test Results 900 W 1 Motor A B T2 Upper Ring A T3 Lower Ring T4 Lower Ring 9 x o o LT 100 Time s Figure 8 2 Thermal transient test results 20 Source PSC Document 2000715A 30 July 2014 www planetarysys com Page 48 of 88 2000785F MLB User Manual Planetary Systems Corporation 9 Shock Properties 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 band frequency and 5 damping Shock testing has consistently produced the determination that the Lightband substantially attenuates shock in a typical flight stack 9 1 Maximum Shock Generated by Lightband To characterize shock produced by the Lightba
41. 0 24 Analysis 30 July 2014 www planetarysys com Page 25 of 88 2000785F MkII MLB User Manual Planetary Systems Corporation Axial line loading arises from axial X and lateral Yig or Zig loading whereas shear line loading arises from only lateral Yig or Zig loading 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 Fy 4VCMy eq TE 1 n nD 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 o
42. 061 6 per AMS QQ A 40001 4000107 Separation Connector 000106 amp 400010 250 11 Vespel SP 1 BeCu Separation Switch 4000383 Al Aly Stainless Steel Gold Roller Spring Proprietary 300 Series Stainless Steel Roller Spring Base 4000426 300 Series Stainless Steel Roller Spring Slider 4000427 300 Series Stainless Steel Leaf Fasteners Proprietary A 286 Assorted Fasteners pa 300 Stainless Alloy Steel Bronze Stainless Glass Filled 9 Pin Connector HDC9S2000S DAP Gold Leaf Retaining Cord 4000629 us Rin pere Staking Compound Arathane 5753 A B LV Vacuum Grease Braycote 601EF Dry Lubricant E Molybdenum Disulfide Powder 1 Per MSFC STD 3029 Vendor 5 3 Q o 2 z o Q Q o Q O D 4 J J 5541 CI 3 Hard Anodize per MIL A 8625 Type Ill Class 1 Electroless Nickel per AMS C 26074 Class 4 Grade B Electroless Nickel per AMS C 26074 Class 4 Grade B Electroless Nickel per AMS C 26074 Class 4 Grade B 5 e O Y Y PSC Y Y PSC Y Y PSC Y Y U varies Hard Anodize per Mil A 8625 Type Ill Class 1 Hard Anodize per Mil A 8625 Type Ill Class 1 Hard Anodize per Mil A 8625 Type Ill Class 1 Passivate per AMS QQ P 35 Type II PSC N PSC N PSC N PSC N Proprietary Proprietary Proprietary Proprietary Proprietary Hard Anodize per Mil A 8625 Type Ill Class 1 Black anodize MoS2 Chem Conv color gold per Mil DTL 5541 CI 3
43. 065 0 065 0 065 0 065 0 065 0 005 0 005 0 005 0 005 0 005 0 005 0 005 0 005 0 005 0 005 0 007 0 007 0 007 0 007 0 007 0 007 0 007 0 007 0 007 0 007 0 002 0 002 0 002 0 002 0 002 0 002 0 002 0 002 0 002 0 002 68 to 68 to 68 to 68 to 68 to 68 to 68 to 68 to 68 to 68 to 145 146 147 148 149 150 151 152 153 154 Loading amp Boundaries Required flatness of adjoining structure if xxxx structure is stiff in 7 Nominal Separation Signal Mean Time to Separate s 24 32V nominal temperature Std Dev Time to Separate s nominal voltage amp temperature oO o Resistance from Upper Ring to Lower Ring 7 Thermal Resistance C W Survival Limits C 8 Operating Limits C 8 0 081 128 128 128 128 128 128 128 128 128 128 0 35 0 35 0 35 0 35 0 35 0 35 0 35 0 35 0 35 0 35 0 84 0 84 0 84 0 84 0 84 0 84 0 84 0 84 0 84 0 84 505 5 709 768 937 Solar Absorptivity a Emissitivity s Generated Shock at Upper Ring 100 Hz 9 Generated Shock at Upper Ring 1 000 Hz g Generated Shock at Upper Ring 10 000 Hz g Maximum Rotation Rate deg s 617 1 038 6 6 7 7 7 8 8 9 9 9 7 4 8 9 46 80 68 80 46 80 68 80 4 4 4 4 4 8 2 6 1 1 1 1 1 1 1 1 1 1 1 1 38 5 5 6 70 7 7 9 Nominal Rotation Rate deg s Separation Velocity
44. 18 3 See Table 18 3 0 05 Shall not be measured provided by analysis Inertia lb in about CM 1 Shall not be measured provided by analysis Shall not be measured provided by analysis measured from MLB origin LB Shall not be measured Ensured va fixture precision Shall not be measured Ensured via fixture precision 1 0 1 0 1 0 5 0 Motor s Powered Duration Deploy s 0 050 Rotation Rates deg sec Acceptance Trials Commanded Voltge V Acceptance Trials Motors Powered A B Both Figure 18 7 Standard separation reliability test requirements for a separating mass gt 200 Ibs Typical Separation Reliabilty Test Results Pees ee ee oe Ir SPs eee ee Nee 7 Figure 18 8 Typical Separation Reliability test results 30 July 2014 www planetarysys com Page 71 of 88 2000785F MLB User Manual Planetary Systems Corporation Reference Data Motors i Yaw Roll Kinetic Predicted Predicted Trial Spring Cfg No File Powered paul i Flight Flight Me Qty Axis Velocity Velocity m s ft s Tuning Trials Acceptance Trials 2 11 2 deploy 002 1901 1872 280 27 083 21 338 2426 0 603 0 097 0 720 0 566 0 271 1 548 9 60 0483 1585 3 tt 2 deploy 003 1901 1869 280 22 791 27 065
45. 30 July 2014 www planetarysys com Page 6 of 88 Planetary Systems Corporation 2000785F MLB User Manual LI CO Jj COLI 4 E LF r M d 7 Figure 2 3 Four and one Lightbands used to separate five spacecraft on STP S 26 in November 2010 7828 Oo N A 5 gt o c 2 Xx j gt c E E M o 7 re D o o E gt jum c Q Qo T L LLI a 2 lt N gt 5 D LL 30 July 2014 2000785F MLB User Manual 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 30 July 2014 www planetarysys com Page 8 of 88 2000785F MLB User Manual Planetary Systems Corporation _ y Figure 2 7 Lightbands on STP 1 an Atlas V idi L 4 Figure 2 8 Two Lightbands installed on a lunar payload prior to launch 1 Source http www nasa gov sites default files adee encapsulation jpg 30 July 2014 www planetarysys com Page 9 of 88 2000785F MLB User Manual Planetary Systems Corporation 3 Why Choose Lightband The Lightband has many advanta
46. 59 15 1 LIGHTBAND SELECTION STEER St a aridus aoe acne ed le tht i pe ie usar Ope td 60 15 1 1 FROG TIS TSF EE 60 152 Belemmesilthiess TedulFemebhlls d E spo dte ebat con Rudd obe eleg anf de 60 15 53 Determine strenotDiregultemerils 25 toss ahud Linee Posh UC Bono newts Ga uet Gaeta 60 15 1 4 Determine cyclic loading and fatigue requirements nnt nenne nnns 60 1515 Selecta Lightband bota didi det euet um Me d et uie 60 15 1 6 Determine payload and tinal stage 8 5 otveannalaveni isin 60 15 1 7 Determine separation velocity requIreMON wesc 60 15 1 8 Determine Separation Switch 61 15 39 Beienmtde E EEE tania eels 61 15 1 10 Determine Roll Bracket quantity Lightband will be classified as 0 61 15 1 11 Determine Lightband Compression Tool quantity Lightband will be classified as 61 15 1 12 Complete virtual it eheck and plan IOGISUCS ss c icit see aa Bua Ra 61 15 1 13 Brace
47. 8 2000785F MLB User Manual Planetary Systems Corporation 9 2 Maximum Shock Applied to Lightband Figure 9 6 and Table 9 2 show maximum shock applied to the in previous tests 9 The was exposed to this shock input times in each of the 3 Lightband axes 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 and the Lightband did not auto actuate Maximum Shock Applied to Lightband 100 000 10 000 5 2 1 000 5 lt 100 Upper Tolerance Test Level Lower Tolerance 10 100 1 000 10 000 Frequency Hz Figure 9 6 Maximum shock applied to Lightband at Lower Ring interface dde 8 Table 9 2 Maximum shock applied to Lightband 48 1 692 26 Source PSC Document 2002081F 30 July 2014 www planetarysys com Page 52 of 88 2000785F MLB User Manual Planetary Systems Corporation 10 Reliability Probability of Success Confidence Level gt 0 999 gt 0 999 gt 0 998 gt 0 998 Table 10 1 Minimum reliability and corresponding confidence level Table 10 1 was calculated using Table 22 4 of Space Vehicle Mechanisms by Peter L Conley given approximately 1 000 no failu
48. ACCEPTANCE w 66 18 1 STANDARD ACCEPTANCE TESTS ccscececcecscscaccececscucaucusesscucatausesecueatausesecueatausesecsuecseneausesecsentausesecsentausesecseutauaeatausecseutauaesecseusanaesenees 66 18 1 1 Fandom Ec souci orci Usted eta f ee UAE 66 18 1 2 Thermal Vacuum Test ER RR RE uc 68 ee o doe EOS di du iom mad dae tois tested oie ted 70 18 2 CUSTONJACGEPTANGEJESTS beoe crece teat atop enin cum a i ar e lite cu Vestes i tt tas E dnd ae 74 2 reer ee nee 74 18 2 2 OO o i RD hte oaths aces nate 76 19 QUALIFICATION TEST ING es occas ere acs eg 78 19 1 RANDOM VIBRATION QUALIFICATION FEST chase Li nee ue ties 78 19 2 THERMAL VACUUM QUALIFICATION VES tr Mami E cedi Ld E e nu ce A d Ld DU C c e 79 19 3 SIRENO TA QUAN OA ON ES alate detenta aliu anas tSt Atte sad sadi s I ton cca etes
49. 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 C 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 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 30 July 2014 www planetarysys com Page 24 of 88 2000785F MkII MLB User Manual Planetary Systems Corporation 6 10 Line Load Limits Line loading in the axis arises from loads in the direction and moments about the or Zig axis Generally the moments about Yip and 4 g
50. July 2014 www planetarysys com Page 61 of 88 2000785F MLB User Manual Planetary Systems Corporation ipta Yes Add Roll Bracket req 15 1 1 Read manual Brackets to SOW needed 15 1 2 Determine eded 77 AGG LCT req to SOW stiffness LCT aty needed Add LCT req to SOW requirements 15 1 3 Determine 15 1 12 Virtual fit strength check requirements Testing 15 1 4 Determine 15 1 13 Determine non Add non standard fatigue requirements test regimen standard test regimen to SOW 15 1 5 Select 15 1 14 Select Flight diameter or EDU 15 1 6 Determine 15 1 15 Specify a payload amp FS mass Lightband Contact PSC w SOW Were any order CUSTOM answers Lightband yes 15 1 8 Determine Contact PSC order Sep Switch qty STANDARD Lightband 15 1 9 Determine Sep Conn qty 15 1 7 Determine Sep Vel Req 15 1 10 Determine Roll Bracket qty Figure 15 3 Lightband selection process flow chart 30 July 2014 www planetarysys com Page 62 of 88 2000785F MkII MLB User Manual Planetary Systems Corporation 16 Purchasing Deliverables amp Schedule 16 1 Purchasing a Lightband Lightband prices are listed on the GSA Schedule Contact PSC directly to receive the most up to date prices The standard payment schedule is shown in Table 16 1 Payment Receipt of order 80 Build complete review completion 1 1 25 J O Shipment Table 16 1 Standard paymen
51. LYSIS FMEA 1 neces eene ee nee nenne nnnm nn nnn nnn sana sauna auras 54 12 CLEANLINESS amp HANDLING 20 2 05 21 45 0 8 69 0063 sence OREL Der Ea dL Eo ER tract Dor Ee cL Eo Ec eoe nnmnnn 55 12 1 CUSTOMER CLEANLINESS AND HANDLING HEQUIREMEN TS ds scu dae ea du deco moa dee v quoe tech men o ee med ave pono tem een 55 12 2 CLEANLINESS AND HANDLING BO usc ettet tette o piove e beet in bs 55 12 3 CIHEANBINESS PRECAUTIONS oon a eid ei ar M MD E e LOO MA nC cae hich ot ceed AMA 55 13 STORAGE REQUIREMENT S S 56 14 LIGHTBAND OPERATION amp INTEGRATION cccececeecececececcececececnenececececnenecececneneneneeacnenensnenenecesaeneneaeeuseeneneneeueaeneaeaeeuenensneneaeaeeneas 57 14 1 6 E UU LL Lu i Pied M c eiie EE UE A tte ed CL S Eee LR I EA IIS 57 14 2 VERTICAL AND HORIZONTAL INTEGRATION TO ADJOINING VEHICLES 57 30 July 2014 www planetarysys com Page 2 of 88 2000785F MLB User Manual Planetary Systems Corporation 15 SELECTING A LIGHTB AND othe cece el oe ee ae
52. Lower Ring 30 July 2014 www planetarysys com Page 38 of 88 2000785F MLB User Manual Planetary Systems Corporation Matar Stow 2 0 1 5 2754105 1 0 15 5 1 0 5 1 Voltage V y juan 0 5 o tm 0 0 Current Motor A y 7 Current Motor 9 5 10 Voltage Motor A 40 Voltage Motor B Circuit to STOW the DEPLOYED Switch ur 00 020 40 0 8D 0 80 1 00 135 Circuit to SET FOR STOWED Switch state Lightband state prior to stowing FLIGHT the Lightband prior to SET FOR operation FLIGHT operstion Time sec Hotes 1 See latest revision of PSC document 2000781 MLB Opersting Procedure for best voltages Larger DEPLOYING 2 Lightbands generally require higher stewing voltages SETTING FOR FLIGHT 2 2 Only operate the Lightband if operator has passed PSC s training course NO Current Motor A Deploy Current Motor B Voltage Motor Voltage Motor Voltage V 5 Juans y 28 0 4 0 Current Motor vidc 1 Current Moor B AM Voltage Motor 10 0 5 Voltage Motor 0 05 0 10 0 15 0 20 0 25 0 30 Time sec 15 0 00 0 25 0 50 0 75 1 00 125 Time sec Circuit to DEPLOY the BE PPOR FIGHT Sath Lightband initiate state prior to DEPLOY separation operation Figure 7 2 Schematics to stow set for flight and d
53. PLANETARY 2303 Kansas Avenue silver Spring MD 20910 SYSTEMS 301 495 0737 CORPORATION info planetarysys com PSC 2000785F MLB User Manual 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 EN E US Patents 6 227 493 6 343 770 6 390 416 2000785F MLB User Manual Planetary Systems Corporation Table of Contents 1 PE VISION PAIS TOP 5 ee ees ee oe pee th ts Se Soe oe 4 2 INTRODUG TION 6 3 WHY CHOOSE LIGHT BAND 222 2 2 2 5 63 2 0 00905 220 LOTES RES EO secede Ee Eco aea EE 10 4 LIGHT BAND FLIGHT HISTORY RR o 11 5 LIGHTBAND CAPABILITIES AND DIMENSIONS nnmnnn 12 6 MEGHANIGAL PROPERTIES a cc 13 6 1 E E E ESEE 13 62 TOLERANCE ON DIMENSION mers side A n atc tee aie heared iN ah tae E E tM 14 exc MES M cias BB message
54. PSC Maxon Proprietary PSC varies PSC Chem Conv color gold per Mil DTL 5541 CI 3 Chem Conv color gold per Mil DTL 5541 CI 3 2 PSC 3 PSC no Honeywell PSC Proprietary 2 N er Proprietary Proprietary varies Vlier Hard Anodize per Mil A 8625 Type Class 1 McMasterCarr PSC Electroless Nickel per AMS C 26074 Class 4 Grade B 3 3 5541 4 PSC 3 Q o 5 o 9 Q o Q O 4 m N PSC N Y Proprietary 7 Passivate per AMS QQ P 35 Type Il PSC Co N N N N N N N N N N N 8 N N Passivate per AMS QQ P 35 Type Il PSC varies N N varies Positronic Ind 42 PSC AR Huntsmann Castrol varies Table 6 8 Lightband materials and surface treatments 10 Source PSC Document 2000849A MLB Materials and Surface Finish List 30 July 2014 www planetarysys com Page 32 of 88 2000785F MkII MLB User Manual Planetary Systems Corporation 6 18 Part Marking 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 6 19 Subsystem Weights Unit PSC part number Weight Ib The Upper Connector may be placed on either the Upper or the tea 4000107 0 025 Lower
55. 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 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 30 July 2014 www planetarysys com Page 88 of 88
56. a gt 10x than the separating vehicle It also assumes the pre separation rates are all zero Only Separation Reliability testing can produce verifiable values for rotation rates See Section 18 1 3 Payload Mass m and inertia 1 Figure 6 29 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 115 the mass moment of inertia about the center of mass of the separating vehicle Rotation Rate vs CM Offset a opoo HEN MPa 0 000 0 002 0 004 0 006 0 008 0 010 0 012 0 014 CM Offset d m oo degs Figure 6 30 An illustration of Equation 4 30 July 2014 www planetarysys com Page 35 of 88 2000785F MLB User Manual Planetary Systems Corporation The Separation Spring configuration may be adjusted on the Lightband so the Springs as a sum act through the CM However it may be easier to move the CM The lower the v required the lower the rotation rates of the payload 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 Equation 5 is used to calculate separation ve
57. acuum as a simulation of in flight conditions At the last cycle s extreme temperature the Lightband will be deployed Upon completion of cycling in partial vacuum the test item will be removed from the chamber and formally inspected to verify that it still operates nominally Standard Levels See Figure 18 3 Thermal dwell time has been specified as 210 minutes 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 Number of separations One 1 at the end of thermal cycling Thermal Vacuum Testing Source Document s PSC Document 2000785E User s Manual for Mark II Lightband Test Objective Demonstrate that the test item operates nominally after thermal and pressure cycling Test Complete Criteria 1 The test item deploys nominally at each designated step 2 The test item is inspected IAW PSC Document 2001066 MLB Inspection Report upon completion of thermal vacuum cycling 3 All attendees of the PSC internal Test Complete Review TCR approve the test plan and results 1 In a separation springs travel at least 0 7 inches in an initiation springs travel 0 0 inches 2 PSC does not guarantee pressure will remain below 1 0E 4 Torr at temperatures above 23 C for first several cycles 3 A bake out occurs after chamber is closed Max bake out temp shall be whichever is greater requ
58. and 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 3 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 FETT z1 SEa 157 1 Figure 6 27 A rendering of CSA s SoftRide OmniFlex which isolates the satellite from the launch vehicle loads 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
59. astened to the Motor Bracket Section 7 of this document describes electro mechanical operation of the Lightband Bevel Planetary Gears ee Sliding Tube i Ball Nut oom SE Mss Deploy End Plate Stow Limit Switch Stow End Plate Deploy Limit Linear Way Deploy Stops Switch Figure 6 12 Motor Bracket Assembly shown in the stowed state with Sliding Tube shown as section for clarity 30 July 2014 www planetarysys com Page 19 of 88 2000785F MLB User Manual Planetary Systems Corporation Figure 6 13 Motor Bracket Assembly in the stowed state Figure 6 14 Motor Bracket Assembly in the set for flight state Figure 6 15 Motor Bracket Assembly in the deployed state 30 July 2014 www planetarysys com Page 20 of 88 2000785F MkII MLB User Manual Planetary Systems Corporation 6 6 Stiffness Stiffness is major design driver when determining which Lightband size is required for a payload Payload stack stiffness increases with the cube of the Lightband diameter For example a 15 inch diameter Lightband is about 6 6 times stiffer than an 8 inch diameter Lightband but weighs only twice as much Additionally the first lateral mode frequency of the payload stack increases with the 3 2 power of Lightband diameter Often customers select the smallest allowable Lightband and thus payload stiffness is barely above allowable minimums This
60. ay be combined for tolerance evaluation purposes 3 If additional accelerometers are added during test they shall follow the same naming convention wherein C signifies control and R signifies response 4 Narrow Bandwith Exceedance tolerance is the maximum width that a control signal may exceed the control tolerance and still be considered acceptable Notes Random Vibration Profile Fea oor 100 0790 000 100 000 48100 694 40 0190 000 151 000 11642 1079 2 000 Random Vibration Tolerances Lower Ctrl Vibration Upper Ctrl Limit 6 5 Limit ASD eee Profle ASD me 28 E Random Vibe Profile Freq GHz G Hz E __ a ES 31 E Hz H Limit Abort 0 0260 0 7960 0 399 Ind Hl Ll 01990 0 1990 60 0 1590 0 317 0 080 2 000 0 0143 0 029 0 007 25 Verify control strategy EDE Parameters Parameter Value Tolerance ASD G Hz o Overall Gira Duration per axis sec 10 0 Axes 100 10 000 Frequency Hz NBE Tolerance 4 100 Crtl Accel Crosstalk Upper Limit Grms In axis input level Random vibe DOF per channel 10 Data Sampling Rate Hz 5 000 Figure 19 1 Previously executed qualification random vibration test parameters Max Ctrl Bandwidth Hz 20
61. band resulting in stalled Motors for approximately 60 seconds The most common customer errors arise when they fail to follow procedures properly or fail to verify electrical connections These failures typically occur 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 30 July 2014 www planetarysys com Page 54 of 88 2000785F MkII MLB User Manual Planetary Systems Corporation 12 Cleanliness amp Handling 12 1 Customer Cleanliness and Handling Requirements Users shall store and operate the Lightband in a visibly clean environment The Lightband shall be covered when not in use The Lightband may be handled without gloves as long as handling precautions outlined in 2000781 MLB Operating Procedure are followed 12 2 Cleanliness and Handling at PSC The Lightband is assembled and tested in a visibly clean environment The thermal vacuum acceptance test that every Lightband undergoes tends to boil off volatile contaminants 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 Section 24 outlines the contamination control methods used in shipping 12 3 Cleanliness Precautions The Viton bumpers can sh
62. bly 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 Figure 7 4 Through holes on the outer lip of the Lightband Upper and Lower Ring exist for routing tie wraps to support harnesses 30 July 2014 www planetarysys com Page 40 of 88 2000785F MLB User Manual Planetary Systems Corporation 7 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 7 5 Separation Connector as described in PSC Document 2001025 Separation Connector Data Sheet The connectors have been extensively tested in shock vibration and thermal vacuum environments Product benefits include Prevents incorrect Lightband alignment a keying feature e Separates in parallel with the Lightband to ensure minimal induced rotation ship 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
63. can increase risk of mission failure due to unintended stack dynamics Prudent customers often use a larger Lightband diameter than required to gain stiffness margin with only a small increase in weight The method used to determine stiffness of the Lightband is shown in the latest revision of PSC Document 2000541 Lightband Stiffness Stiffness values are shown in Table 5 1 Higher fidelity stiffness estimations of the Lightband can be determined via FEM Moment A Moment Distance Axial Load Distance Axial Load Payload Payload from from base of base of Lightband Final Stage Final Stage Recommended Not Recommended Largest Possible MLB Bolt Circle Smallest Possible MLB Bolt Circle Diameter Diameter Figure 6 16 Larger diameter Lightbands are stiffer and stronger than smaller diameters 6 7 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 6 2 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 6 2 Normalized Normalize
64. ce of adjoining structure before integration and adequately plan for any likely issues See Table 6 4 Lightband Adjoined to oT Stiff Weldment Ring or Plate Transition Rings Isolation System EFE Flight Adjoining Adapter plate Adapter cone or ring Isolation system Structure Often difficult to manufacture within Typically meets flatness requirement Reduces flatness requirement Flatness required flatness tolerances EE EER Often too stiff does not allow Lightband to p der d dim i Provides best chance for successful Lightband Flexure flex enough during operations a q 9 Lightband integration and operation Difficult to meet flatness requirements via Less difficult to meet flatness requirements eee dup an Not necessary Shimming shimming via shimming Relative Cost to Relative Cost to Ensure A E Side View SS Warum mcus am A f YN rm goo 999 T Isometric View Table 6 4 Comparison of Lightband adjoining structures 30 July 2014 www planetarysys com Page 23 of 88 2000785F MLB User Manual Planetary Systems Corporation 6 9 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 displaye
65. 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 during 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 30 July 2014 www planetarysys com Page 41 of 88 2000785F MLB User Manual 7 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 event to either adjoining vehicle A full description of PSC s Separation Switch can be found in PSC Document 2002204 Separation Switch Data Sheet a 4 T 1 d Figure 7 6 Separation Switch as described in PSC Document 2002204 Separation Switch Data Sheet 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 30 July 2014 www planetarysys com Page 42 of 88 2000785F MLB User Manual Planetary
66. d Duration s 7 Max Allowable uis Pod Deflection Gage Placement i ae nts Jut Figure 19 3 Previously executed qualification strength test parameters EE A Increment Increment Increment 6 Increment a coe Increment 102 5 Increment Decrement a 30 Source PSC Document 2002305 31 Source PSC Document 2002319A 30 July 2014 www planetarysys com Page 79 of 88 2000785F MLB User Manual Planetary Systems Corporation 19 4 Shock Qualification Test Tested applied shock parameters on a 15 inch diameter Lightband are shown in Figure 19 4 Qualification Shock Testing Source Document s PSC Document 2002081F Test Objective Measure the maximum shock that the test item produces Test complete criteria Notes Demonstrate that the test item operates nominally after exposed to shock loads 1 The required shock profiles are applied to the test item in the specified axes 2 Shock produced by the test item is measured 3 The test item separates nominally after being exposed to required shock profiles 4 The test item is inspected IAW PSC Document 2001066 MLB Inspection Report upon completion of shock exposure 5 All attendees of the PSC internal Test Complete Review TCR approve the test plan and results 1 In a separation springs travel at least 0 7 inches in an initiation springs travel 0 0 inches 2 Test Spectrum must also be 50 above the Nominal SRS 3 Upper t
67. d Normalized amp Zip Axis Rx Rotational Stiffness Ry or Rz Rotational Stiffness Stiffness Normalized Axis Stiffness Lightband without joint compliance Table 6 2 The effect of joint compliance on stiffness 6 8 Discussion of Features on Adjoining Structures In order to maximize the stiffness of the satellite stack including the Lightband engineers should design robust features in the structures adjoining the Lightband As the analysis in Table 6 3 shows thick flanges small moment arms and chamfers or large radii create much stiffer and lighter structures 3 Source Moog CSA Engineering Document 20008507B and PSC Document 20005414 30 July 2014 www planetarysys com Page 21 of 88 2000785F MLB User Manual Planetary Systems Corporation Max Deflection Plot Design Notes Deflection Value in e Flanges too thin 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 6 3 Features of adjoining structure The stiffness of 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 st
68. d degradation during any test at specified bolt preloads 1 4 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 beneficial 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 22 00 25 SHC screws recommended and small pattern washers NAS620C416 etc required 10 screws can be accommodated with appropriate shoulder washers Figure 6 19 1 4 inch fasteners from Lightband to adjoining structures Smaller fasteners such as 10 are also acceptable for use but must be approved by PSC Contact PSC to discuss the use of any fastener size other than inch 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
69. e 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 6 12 Damping Ratio Damping ratio may be used to calculate the response of a structure attached to the Lightband A greater damping ratio reduces 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 30 July 2014 www planetarysys com Page 28 of 88 2000785F MLB User Manual Planetary Systems Corporation Response Accel Fi ee E TESTPLaN Z3 258 es TEST ASS EX 4938418 Rey B Eis na LB AXES X _ 1 DATE 3 Control Accel em e ELLA FUR m Lightband fum lt n Figure 6 25 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 t
70. ed 30 July 2014 www planetarysys com Page 5 of 88 2000785F MLB User Manual Planetary Systems Corporation 2 Introduction The Lightband is a space vehicle separation system It is used to separate space vehicles from 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 manual is based on the experience of providing more than 100 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 manual for the Mark Il Motorized Lightband only The be uniquely identified from other Lightbands On the motors are on the outer diameter of the unit Payload separation system 45 on orbit operations TRL9 8 00 to 38 81 inch diameters Canisterized Satellite Dispenser CSD Cubesat deployer Flight heritage TRL9 30 60 120 amp 270 sizes Figure 2 1 MLB separates Space Vehicles from Launch Vehicles CSD is another PSC product for smaller space vehicles Figure 2 2 Two of NASA s lunar GRAIL satellites separate from a Delta Il in 2011 using 2X MLB19 848
71. ed 0 005 square inch debris if the Lightband is stowed and deployed beyond its useable life See Figure 6 12 for an image of the Viton Bumpers and Section 6 15 for discussion of Lightband usable 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 In extreme cases this could lead to cracking of Motor Assembly components or debris creation 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 and molybdenum disulfide mixture 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 See 2000781 MLB Operating Procedure for additional details 30 July 2014 www planetarysys com Page 55 of 88 2000785F MkII MLB User Manual Planetary Systems Corporation 13 Storage Requirements Store the Lightband in a sealed enclosure in relative humidity of less than 95 at temperatures between 0 and 50 C If possible store the Lightband in the deployed state to minimize strain on components The maximum allowab
72. ed custom work This section is intended as a reference to present proven limits of the Lightband during previous environmental qualification tests 19 1 Random Vibration Qualification Test Tested vibration parameters of a 15 inch diameter Lightband are shown in Figure 19 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 Qualification Random Vibration Testing Source Document s Test Objective Demonstrate that the test item operates nominally after vibration loading Test Complete Criteria 1 The required random vibration profiles are applied to the test item in the specified directions for the specified durations 2 The test item separates nominally after being exposed to all random vibration profiles 3 The test item is inspected IAW PSC Document 2001066 MkII MLB Inspection Report upon completion of vibration exposure 4 All attendees of the PSC internal Test Complete Review TCR approve the test plan and results 1 In a separation springs elongate at least 0 7 inches in an initiation springs elongate 0 0 inches 2 Control bandwidths m
73. emoved measure generated shock from test objective e Section 19 Simplified section figures and data e e Section 19 1 Removed MLB38 qual vibe test info Section 20 Removed delaminated staking example added accessible to step 4 e Section 21 Consolidated subsection on wiring harness design into Section 7 3 e Section 23 Added training content and training expiration duration e Section 24 Updated IAW latest practices e Figure 2 1 Updated flight heritage values e Figure 6 12 Updated with latest revision of MBA e Figure 6 13 through Figure 6 15 Updated with latest revision of MBA e Figure 6 20 Updated e Figure 6 32 Updated to reflect realistic Separation Spring quantities e Figure 7 9 Updated to latest version of profile display program e Figure 9 2 Added e Figure 9 3 Updated for clarity e Figure 9 4 Updated plot with improved formatting e Figure 9 5 Updated plot with improved formatting e Figure 15 1 Updated with latest PSC processes e Figure 18 9 Updated e Figure 18 11 Updated to remove MMI measurement changed inputs e Figure 18 12 Updated image e Figure 18 13 Added e Table 5 1 Updated values changed format increased max loads moved location e Table 6 10 Corrected stored energy values e Table 9 1 Added e Table 10 2 Updated quantity of Lightband operations before delivery e Table 15 1 Added e Table 18 2 Added e Table 22 1 Added that LCTs can be purchas
74. ems Corporation Standard Lightband Custom Lightband e No deviation from current Lightband design e Any tests not in standard regimen e Only 3 reqs supplied by customer sep e Any deviation from standard test velocity payload mass amp final stage mass requirements e Random vibration test e Any requierment or contractual obligation e Thermal vacuum test not in this User Manual e Separation reliability test Additional cost e Additional schedule duration Figure 15 2 Standard vs Custom Lightband characteristics Custom Lightband Inquiry Item Document Reference Section Response Y N Is strength testing required Is shock testing required Is any non standard test required Are Roll Brackets required d Oe RE o Are Lightband Compression Tools required A MEE See Is a custom design modification feature required Are non standard rotation rates required Is a separation velocity tolerance tighter standard 25 value Are requirements outside of this User Manual being referenced in a statement of work or separate compliance document If any of the above are answered as yes the Lightband shall be classified as Custom Table 15 1 Standard vs Custom Lightband selection checklist Note checklist is not all encompassing there may be additional unlisted items which necessitate Custom classification 15 1 Lightband Selection Steps The following steps shall be completed by the customer to
75. enerate higher line loading than axial loads In other words lateral load cases are the limiting factor in strength margin ce Fx axial force o o SS Maximum Axial Line Load x force bolt Maximum Shear Line Load Q force bolt Figure 6 20 Line loading forces Force per Bolt Yield Limit Ib bolt Ultimate Limit Ib bolt 22560 Axial 1880 0 2256 0 or Zig Shear 774 0 928 8 Table 6 5 Line load limits In Table 6 5 the and 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 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 All testing at PSC is performed with 1 4 inch fasteners because PSC test cells have 14 28 accepting threads 7 Per PSC Document 2002319 Rev A Lightband Loading Capability Proof Test 8 Per PSC Document 2002286 Rev D MLB15 00
76. eploy 7 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 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 Brack
77. equired This typically occurs with payloads being horizontally integrated or when the payload mass is relatively small 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 required is approximately one pair per Separation Spring as each pair provides approximately 20 16 of compression force In cases where a high quantity of Separation Springs are installed on a smaller diameter Lightband it is sometimes not possible to install the recommended quantity of LCTs See Section 6 21 Section 14 2 and Table 22 1 for more information 15 1 12 Complete virtual fit check and plan logistics Integrate a CAD model of the Lightband download from planetarysystemscorp com or contact PSC with a model of your payload 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 needed 15 1 13 Determine test regimen PSC performs three standard acceptance tests random vibration thermal vacuum and separation reliability IAW Section 18 1 of this document Optional testing includes strength and shock tests If further testing is required please contact PSC 15 1 14 Select Flight or Eng
78. erating the Lightband before receiving training from PSC will void the Lightband s warranty See Section 23 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 of the Lightband and generally performed at PSC s facility in Silver Spring Maryland Remote training is available at potentially additional cost 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 14 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 14 2 Vertical and Horizontal Integration to Adjoining Vehicles Without Isolation System With Isolation System Vertical Integration Horizontal Integration Transition ring or other Spring rigid structure for compliance stiffness while stowing recommended Extremely difficult to access Spring damper of
79. es of the separating half of the fixture are 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 5 consecutive separations where all requirements are met the test item is formally inspected to verify that it still operates nominally Standard Separation Reliability tests do not account for any center of mass offsets the or Zip axes Performing a Separation Reliability test with anything other than standard levels in Table 18 2 is classified as a custom test and will warrant additional cost and schedule duration Standard Levels See Table 18 2 Predicted In Flight Levels Analysis Because Separation Reliability tests cannot identically match flight mass and CG values PSC provides analytical predictions of flight separation velocity and rotation rates based on test results in the delivered test report Parameter Test Value Tolerance Units Standardized value determined by diameter Payload mass See Table 18 3 See Table 18 3 Rotation rates for Rotation rates for podes Customer requirement Customer requirement Standardized value determined by diameter CMu 1 1000 in CMa 00 JJ J J 000 in separations Table 18 2 Standard separation reliability test parameters
80. et Assembly 13 Source PSC Document 4000697B 30 July 2014 www planetarysys com Page 39 of 88 2000785F MLB User Manual Planetary Systems Corporation 7 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 Additionally poorly designed harnessed can obstruct access to the Lightband fasteners 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 PSC recommends the simplest possible harness design using the smallest quantity of Separation Connectors and switches Figure 7 3 A fully featured 3 0 Ib harness on a 5 2 Ib separation system Users should anticipate the process of attaching the harness 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 While the harness can be passed through the Leaves in the Lower Ring assem
81. f Leaves D is the bolt circle diameter length Mx is the maximum applied torsional moment about the axis Typically negligible in flight loading The values in Table 6 5 were calculated by applying loads produced by Equation 1 and Equation 2 to a Lightband in strength 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 Equation 2 naturally incorporates the load peaking associated with the Motor Bracket Assembly Therefore an additional peaking factor need not be applied for that purpose It is useful to observe that the Lightband behaves structurally like a thin walled cylinder when stowed Line loading may peak in areas where stiffness peaks For example if a MLB15 000 is installed 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 of a satellite 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 6 21 Bolted joints to adjoining structures should be designed at
82. furbishment Updated energy values to stow and deploy Section 6 16 Corrected gage pin diameter from 0 275 to 0 281 e Section 6 19 Corrected Sep Switch Data Sheet number typo e Section 7 6 Removed Lightband nominal electrical profiles section removed measurement schematic and added reference to 2000781 Section 8 2 Improved clarity added table to present data e Section 9 Consolidated figures added tables to present data e Section 10 Updated cumulative Lightband operations total corrected stow energy value changed monitoring reference from a figure to Operating procedure e Section 12 Updated for clarity and added subsections 30 July 2014 www planetarysys com Page 4 of 88 2000785F MLB User Manual Planetary Systems Corporation e Section 12 3 Clarified Viton shedding area to be square inches Added moly to lubricant mixture call out Section 13 Updated and added specific storage life value Section 15 1 Updated with shorter schedule and MLB 15 info Section 17 Added mention of inventory management software Section 18 Removed optional use of Load Cell Link during testing updated testing standards updated number of typical operations e Section 18 1 3 Added discussion of analytical in flight predictions e Section 18 2 1 Changed Criterion 1 conjunction from and to or Clarified that MOS is on yield not ultimate e Section 18 2 1 Added sine burst test option e Section 18 2 2 R
83. g 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 Separation 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 8 4 Thermal Resistance The thermal resistances of the Lightband vary by diameter as shown in Table 5 1 A full derivation is given in PSC Document 2000562 Thermal Resistance Test 18 Source PSC Document 2002305 19 Source Appendix A of Spacecraft Thermal Control Handbook Volume 1 Edited by Gilmore 30 July 2014 www planetarysys com Page 47 of 88 2000785F MkII MLB User Manual Planetary Systems Corporation 8 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
84. ges over competing products 1 iss ey 10 11 12 13 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 verified Each Lightband goes through environmental testing before delivery to prove separation capability on orbit Minimal reset time Lightband can be operated by customers and reset in minutes Competing products require hours to reset 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 45 times Simplified procurement The Lightband is priced on GSA schedule to streamline procurement Ideal for ISS The Lightband can be configured so as not to require auxiliary mechanical inhibits This is useful for unique mission redundancy requirements such a
85. he a 7 is d ed the MM is hoses doa b etinm 70 j2 pt to perform separation 1 00E 05 y Chamber is y vented and test 60 item is stowed A 1 00E 04 7 f 1 A f 7 50 1 00E 03 1 i 40 4 s 1 00E 02 1 r 30 ah 1 00 01 a i if E 5 20 1 00 00 ld i rr 5 o 4 EL 4 100E 01 9 i 4 0H 11 1 00E 02 11 i 8 m 10 4 J 1 00E 03 4 INE V EIE M 20 x N N N w 1 00 04 NN RN VOW gt oa V 78 i 30 25 x ES 1 5 3 E QUE i ELM EA Nl pu 00 0 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 Time min R01 Motor A T01 Lower Ring T02 Upper Ring Pressure Figure 18 6 Sample data from a TVac test with more cycles than a standard test 28 Source PSC Document 2002303 30 July 2014 www planetarysys com Planetary Systems Corporation Page 69 of 88 2000785F MkII MLB User Manual Planetary Systems Corporation 18 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 is repeatedly separated on a 5 degree of freedom test fixture For each separation the separation velocity and rotation rat
86. he 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 C On STS 127 July 2009 CAPE ICU II performed the same mission with additional Lightband separations Le ee 2 Figure 8 1 Three Lightbands used 575 116 after approximately 200 25 60 thermal cycles 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 18 1 2 8 2 Survival and Operating limits _ o
87. he 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 50 as shown in Table 6 6 Axis ZeAxis Measured damping ratio d 0 025 0 069 0 063 Hecommended damping ratio d 0 013 0 035 0 032 Table 6 6 Damping Ratio The damping ratio can be calculated if one knows the quality factor 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 54 3 Where d is the damping ratio 6 13 SoftRide and Lightband The SoftRide Isolation System is a spacecraft vibration and shock isolation system designed to reduce launch vehicle induced 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 Bicycle 105 Table 6 7 Valuable payloads are isolated from detrimental external loading using spring damper isolation systems 30 July 2014 www planetarysys com Page 29 of 88 2000785F MkII MLB User Manual Planetary Systems Corporation SoftRide Systems have several benefits when used in conjunction with the Lightb
88. hree 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 t i al y T a E es LL E EE 4 d a L h 3 2 Figure 17 2 PSC s flight hardware assembly clean room 30 July 2014 www planetarysys com Page 65 of 88 2000785F MLB User Manual Planetary Systems Corporation 18 Acceptance Testing PSC completes three standard acceptance tests Vibration Thermal Vacuum and Separation Reliability on standard flight Lightbands prior to delivery This is part of PSC s quality assurance plan EDU Lightbands do not go through standard acceptance tests Instead they are put through approximately 5 bench top operation cycles Just like during assembly all 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 the definition in MIL STD 1540 However PSC
89. ilable purchased payload integration options Emulates the stiffness of a Lightband Allows for axial compliance when mating the Upper and Lower Rings of the Lightband On the MLB 15 000 24 PSC has used 14 28 socket head cap screws with the head diameter reduced to 0 340 in This eliminates the interference fit described PSC Document 2000781 Table 22 1 Ground support equipment www planetarysys com Planetary Systems Corporation Page 84 of 88 2000785F MkII MLB User Manual 23 Lightband Training Lightband training for up to 8 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 Trained personnel are certified to operate their Lightband s for 24 months after successfully completing training Planetary Systems Corporation Training sessions are incredibly important and reduce mission risk 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 potential unforeseen issues during integration and discuss all possible solutions By having this discussion before customer operations and integration customers will streamline all processes involving the Lightband and prevent expensive program delays
90. ineering Development Unit EDU Lightbands differ from flight Lightbands in that EDUs receive only a bench top separation test rather than a full slate of acceptance testing prior to shipment Customers often purchase an EDU in addition to a flight unit 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 15 1 15 Specify the Lightband Use the convention MLBXX XXX SW SC R T FLT DV PM FM to specify the Lightband you need Separation Roll Lightband End Use Separation Connector Bracket Compression Flight or Velocity Qty Pair Qty Tool Qty EDU ft s XXXXX sw SC R T FT DV PM FM Table 15 2 Lightband specification convention Payload Mass Ib Lightband Bolt Circle Separation Diameter Switch Qty For example MLB15 000 2 1 0 8 FLT 1 396 3000 specifies a 15 inch bolt circle diameter Lightband with 2 Separation Switches 1 Separation Connector 0 Roll Brackets 8 Lightband Compression Tool pairs that will receive standard acceptance testing be used for a space flight have flight separation velocity of 1 0 ft s and separate a payload of 396 Ibs from a final stage of 3 000 Ibs Using this convention will ensure that Lightband requirements are unambiguous 15 1 16 Contact PSC Contact PSC by email info planetarysystemscorp com or phone to finalize the selection and purchase of a Lightband 30
91. ing 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 operational physical limits stow set for flight and deploy are reached All of the set screw junctions in the MBA 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 If 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 f
92. ired high temp or 70 C Thermal Cycle Bake out 3 Max Pressure Hiah Tem Temp No of Dwell Time at Ctrl Temp Duration excluding Bake g Low Temp Tolerance Thermal High amp Low Sensor Temp C min out Torr 2 C Cycles Temp min Location C 1 00E 04 Functional test while test item is in Thermal Vacuum Chamber First Cycle Temp Motor s Operation After ae Operation 1 Voltage V Powered Temp C thermal cycle 20 4 27 0 oe Required Sensor No Location Sensor Y N Y N R01 RTD TO TO2 Tcope TO Tcope T04 Tcope J TO Tcope TO Tcope 07 Tcope J j TO Tcope Figure 18 3 Standard Thermal Vacuum test requirements Heat Chiller PSC Test Thermal Vacuum Rack Chamber Shown without lid Figure 18 4 4X MLB11 732 inside the PSC Thermal Vacuum Chamber 30 July 2014 www planetarysys com Page 68 of 88 2000785F MLB User Manual Standard TVac Test Thermal Profile 80 Bakeout 70 60 50 40 9 5 lt 20 8 10 Cycling 0 B 10 20 40 Cycle Number 1 2 3 4 Separation Time Figure 18 5 Standard TVac test thermal profile 80 1 00E 06 Pressure spikes as software shuts down after completion of the 7th thermal le the chambe held at partial vacu ht T
93. irement 4 5 A trial is defined as meeting the Shock Requirement in that axis ie one impact could meet the shock in all 3 axes See 2000785 User s Manual for Lightband for criteria to determine if a shock test is required Applied Acceleration g 100 000 Lower j y 600 30 60 _ Ee ar a 3 000 1 500 3 000 PS eae 10 000 1 500 3 000 INN RU LCD NR 1 000 Frequency Hz Functional Test Following All Trials Accelerometer Locations Voltage MOINS Accel NECE Accel Axial Separation or Desianaioh Accel Type Planar Location Initiation B Both 9 Location L Acceleration Nominal lil L Test Stack Location Weight Ib o Dem vaen Ring Figure 18 15 Example of custom shock test requirements 30 July 2014 www planetarysys com Page 76 of 88 2000785F MkII MLB User Manual Planetary Systems Corporation Hammer T TEVASS Y N Figure 18 16 A shock test of an MLB11 732 performed on PSC s shock test fixture 30 July 2014 www planetarysys com Page 77 of 88 2000785F MkII MLB User Manual Planetary Systems Corporation 19 Qualification Testing Various diameters of Lightbands have received qualification environmental testing on multiple occasions Qualification tests of Lightband diameters shown in Table 5 1 are generally not required and shall be consider
94. le materials Anomaly reporting HE NN Phase Il Build and test Lightbands to Phase Firm fixed price HE EM results Any Any to be determined or any Cost plus fixed change to change in requirements that exceeds Mediators TOP KONANG fee or time and Phase specifications in Phase materials Table 16 4 Typical custom Lightband program Complete specification of the Phase customization Figure 16 1 Custom work example modified Upper Ring for an MLB31 600 Mk Il used on the IBEX program 30 July 2014 www planetarysys com Page 63 of 88 2000785F MLB User Manual Planetary Systems Corporation 16 5 Lightband Deliverables The items included in the price of a Lightband and delivered to the customer are 1 Lightband s 2 The production log which provides detailed traceability of parts procedures and other materials It is also a complete build log of the Lightband 3 Copies of all as run test procedures and reports 4 Certificate s of conformance 5 Training on Lightband operation at PSC s facility Additional deliverables may be included in the case of custom Lightbands 16 6 Lightband STEP Files STEP files of Lightband assemblies are available to prospective users and customers for download These include models of the Lightband deployed and stowed These models allow the generation of unique Separation Spring Connector and Switch configuration PSC reserves the right to move Separatio
95. le storage durations are shown in Table 13 1 Lightband Max Allowable Storage Before Operating Lightband State Duration years beyond this Storage Duration Set For Flight Contact PSC for approval Deployed Contact PSC for approval Table 13 1 Lightband storage limitations The Separation Springs do not creep due to long term storage and the Lightband can remain stowed and ready for separation The shelf life of a Lightband is estimated to be 20 years but PSC shall be contacted for approval before operation if any of the allowable storage durations given in Table 13 1 are exceeded The most extreme storage environment a Lightband has been exposed to was the STS 116 and STS 127 missions In those cases six Lightbands were on orbit stowed in Shuttle s bay 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 is an extremely rigorous verification of the Lightband s capacity to operate after long term storage In another example a Lightband on the STP S26 mission remained stowed on orbit for more than 90 days because of a satellite communication issue Upon receiving the separation signal from the final stage 3 months later than planned the Lightband separated nominally 30 July 2014 www planetarysys com Page 56 of 88 2000785F MLB User Manual Planetary Systems Corporation 14 Lightband Operation amp Integration CAUTION Op
96. locity and Equation 6 is used to calculate the number of Separation Springs required given a desired velocity between the payload and the final stage w mM mM v x 2nE 6 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 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 6 31 The relative velocity v is created by the Separation Springs S 30 July 2014 www planetarysys com Page 36 of 88 2000785F MLB User Manual Planetary Systems Corporation E J 1 02 n 0 9 m kg
97. mit ASD Profile ASD ASD G Hz ve te 1608 1000 2000 6 25 Verify control strategy EDE Parameters Durationperaxs sec _ 60 10 0 XYZ Control Strategy Ctrltolerance 10 1000 Hz dB 15 Ctritolerance gt 1000 Hz dB 30 __ MaxCmiBandwidth H 5 NBE 20 100 H 10 NBE 100 1000 Hz 4 10 midband teq NBE Tol 1000 2000 Hz 100 Accel Crosstalk Upper Limit 9 axis inputlevel Frequency Hz Accelerometer Parameters Functional Test Following Vibration ini Accel Accel Axial Voltage Motor s Accel Type Planar Operation 1 Designation Location V Powered Location Underside of Control Triaxial top flange of Along Separation Both lower TR Underside of At test director s Control Triaxial top flange of discretion Default tower TR to Along 2 s Topside of 3E lower flange Response Triaxial af upper Along Yip transition ring Figure 18 2 Standard random vibration test requirements Lower Ctrl ASD G Hz 30 July 2014 www planetarysys com Page 67 of 88 2000785F MLB User Manual Planetary Systems Corporation 18 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 v
98. mplished 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 Source PSC Document 2002653 Refurbishment Procedure 30 July 2014 www planetarysys com Page 31 of 88 2000785F MkII MLB User Manual Planetary Systems Corporation However flat head fasteners should not be used to permanently fasten the Lightband to an adjoining structure A gage pin of 0 281 0 005 inch diameter is the nominal diameter that would form a slip fit to the holes on the Lightband 6 17 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 materials in the Lightband are low out gassing as defined by ASTM E 595 total mass loss TML is less than 1 0 anda collected volatile condensable materials CVCM is less than 0 1 All of the materials in the primary load path are highly resistant to stress corrosion cracking SCC as defined by MSFC STD 3029 See Table 6 8 In Primary Highly Load Resistant Magnetic Path to SCC 1 Component Name Part Number Al Aly 7075 T7351 per AMS QQ Lower Ring Varies by diameter A 250 12 or AMS 4078 Y Y Al Aly 7075 T7351 per AMS QQ Upper Ring Varies by diameter A 250 12 or AMS 4078 Lower Hinged Leaf 4000391 0001 10 par AMSG 250 11 U
99. n Spring locations to satisfy rotation rate requirements when PSC completes separation reliability testing on flight Lightbands 16 7 Assembly Drawings PDFs of assembly drawings can be made available to customers before delivery Assembly drawings include bills of material This item is subject to US Export Control regulation 16 8 Lightband Finite Element Models PSC has test verified finite element models FEM of Lightbands available for customers Contact PSC for further information This item is subject to US Export Control regulation 30 July 2014 www planetarysys com Page 64 of 88 2000785F MLB User Manual Planetary Systems Corporation 17 Manufacturing Process Engineers at PSC design assemble and test Lightbands PSC is an AS 9100 compliant organization All of the machining and fabrication is completed by vendors qualified to PSC s standards PSC maintains documentation of all tasks associated with flight hardware procurement storage assembly test and shipment All of these are enveloped by PSC s quality management program Procurement manufacturing and stocking are controlled by inventory management software 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 t
100. nd 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 at the Upper Ring Interface is less than at the Lower Ring interface Since most customers focus more on minimizing shock at the Upper Ring interface because it is attached to a sensitive payload the figures below show Upper Ring interface shock data Max Upper Ring Max Upper Ring Max Upper Ring Interface Generated Interface Generated Interface Generated Shock 100 Hz g Shock 1 000 Hz g Shock 10 000 Hz g Table 9 1 Maximum Lightband generated shock response spectrum at the Upper Ring interface 21 Source PSC Document 2002258 amp NASA HDBK 7005 Section 5 3 4 1 30 July 2014 www planetarysys com Page 49 of 88 2000785F MLB User Manual Planetary Systems Corporation Maximum Lightband Generated Shock at Upper Ring Interface P 6 1 000 Acceleration g 100 10 100 1 000 10 000 Frequency Hz Figure 9 2 Maximum Lightband generated shock response spectrum at Upper Ring interface Lightband Generated Shock Time History 5 0 5 2 T 0 02 0 04 0 06 0 08 Time s 11 Upper Ring X 11 Upper Ring Y 11 Upper Ring Z 11 Lower Ring X 11 lower Ring Y 1 Lower Ring Z 15 Upper Ring X 15 Upper Ring Y 15 Upper Ring Z 15 Lower Ring X 15
101. no more than 0 02 seconds The winding resistance of the Motors is 10 3 O However R varies with temperature T in accordance with Equation 8 14 7 0 R 10 3 1 0 0039 T 25 8 1 Source Manufacturer specifications 30 July 2014 www planetarysys com Page 43 of 88 2000785F MkII MLB User Manual Planetary Systems Corporation 7 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 0 00 0 20 0 40 0 60 0 80 Time to Initiate sec Figure 7 7 Voltage vs time to initiate at various temperatures with a single Motor only at S10 Torr Voltage vs Time to Initiate w Both Motors Voltage V 0 30 0 40 0 50 Time to Initiate sec Figure 7 8 Voltage vs time to initiate at all temperatures with both motors at 310 Torr 15 Source PSC Documents 2002305 2001044 and 2000715B 16 Source PSC Documents 2002305 2001044 and 2000715B 30 July 2014 www planetarysys com Page 44 of 88 2000785F MLB User Manual Planetary Systems Corporation 7 8 Back EMF of the Motors The Motors are connected to each other via bevel gears Motors behave like direct current generators while running If only one Motor is powered the other will generate a voltage almost as high as the voltage of the powered motor but with zero current 30 0 r 3 0
102. oining structure Can be test correlated to increase precision 7 If in doubt contact PSC See discussion of features on adjoining structures in Section 6 8 8 Installing a high quantity of Springs may prohibit the installation of the maximum quantity of LCTs 9 For example on an MLB15 there may be 4 separation switches and 2 separation connectors 4 2 6 Table 5 1 Lightband capabilities and dimensions _ _ _ _ 30 July 2014 www planetarysys com Page 12 of 88 2000785F MkII MLB User Manual Planetary Systems Corporation 6 Mechanical Properties 6 1 Dimensions Lower Ring Upper Rind Upper amp Lower Rings 6 0 Lower Ring YLB Figure 6 1 Top view of Lightband see Table 5 1 for variable dimension values The dimensions shown in Figure 6 1 and Figure 6 3 as variables vary with diameter and are defined in Table 5 1 Dimensions C and D include the separation event 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 7 3 can substantially increase the volume associated with the separation system Upper Ring Mounting Flange Fi oh Lower Ring Mounting Flange Figure 6 2 A sectional view of a 15 inch Lightband 30 July 2014 www planetarysys com Page 13 of 88 2000785F MkII MLB
103. olerance is a guideline not a requirement 4 A trial is defined as meeting the Shock Requirement in that axis ie one impact could meet the shock in all 3 axes 5 See 2000785 User s Manual for Lightband for criteria to determine if a shock test is required Applied Acceleration g 100 000 p Lower Upper 2 8 8 10 1 299 300 425 848 25 848 _ 5986 425 4 5 986 Shock Parameters EE mE Shock Spectrum Type 9 9 20 Axis of Excitation Trials 4 Upper Tolerance 99 48 48 Frequency Hz Functional Test Following All Trials Accelerometer Locations Operation 1 Separation or Initiation L Voltage iin Accel Accel Accel Planar GC AND B Both 9 Location C i Lower Control Triaxial T Along Test Stack Mem Weight Ib Vibe Plate Bottom Vibe Plate Ring Figure 19 4 Previously executed qualification shock test parameters 3 32 Source PSC Document 2002258 30 July 2014 www planetarysys com Page 80 of 88 2000785F MkII MLB User Manual Planetary Systems Corporation 20 Lightband Inspection After assembly each acceptance test and before shipment the Lightband goes through a standardized inspection procedure defined in PSC Document 2001066 Mk II MLB Inspection Report The purpose of the inspection is to characteri
104. ower surface of the Lower Ring of the Lightband is 0 0070 0 002 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 7 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 7 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 7 13 Static Sensitivity The Lightband has no static sensitive parts 30 July 2014 www planetarysys com Page 46 of 88 2000785F MLB User Manual Planetary Systems Corporation 8 Thermal Properties 8 1 Value of Motors in Extreme Thermal Environments T
105. per Plate for E In line Load Cell Lifting Loads Testitem are calculated in the Test Item coordinate system Coordinate all calculations Origin and Test Fixture 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 System Test Fixture Coordinate System Hydraulic 1 Valves and Pump Cart Lower Hydraulic Cylinder Assemblies connecting rod on left hidden for clarity Figure 18 13 Sine burst strength test of an MLB15 30 July 2014 www planetarysys com Page 74 of 88 2000785F MkII MLB User Manual Planetary Systems Corporation Strength Testing Source Document s PSC Document 2000785 Test Objective Demonstrate that the test item operates nominally after quasi static loading Test Complete Criteria 1 The required loads are applied to the test item 2 The test item is inspected IAW PSC Document 2001066 MLB Inspection Report upon completion of all load cases 3 All attendees of the PSC internal Test Complete Review TCR approve the test plan and results 1 Assumes CM and CM are zero RSS of Y and load factors 2 In a separation springs travel at least 0 7 inches in an initiation springs travel 0 0 inches 3 is compression in test item 4 Applied through CM 5 See 2000785 User s Manual for Lightband fo
106. pper Hinged Leaf 4000392 ARAY DOS GOJA 200 8 Hinged Leaf Pin 4000369 Pin E AMO ROHN Leaf Retaining Ring Proprietary PH 15 7 Mo Stainless Steel Retaining Ring Varies by diameter IAM are AM Oe Motor Bracket 4000394 250 11 Al Aly 7075 T7351 per AMS QQ Sliding Tube 4000395 A 250 12 Link Pin 4000496 A 286 per AMS 5732 or 5737 Alloy Steel a PH Stainless 4000493 400 Series Stainless Steel Ball Nut Proprietary Alloy Steel PH Stainless Bevel Gear 4000494 300 Series Stainless Steel Bevel Gear 4000495 464 Brass Motor Support 4000509 Al Aly 6061 T6 per AMS QQ A 250 11 Motor 4000529 Al SST Cu Delrin Neodymium Spherical Plain Bearing Carbon Chromium Steel Al 7075 T7351 per AMS QQ A Link 4000434 250 12 Link Retaining Ring Proprietary PH 15 7 Mo Stainless Steel Gear Cover 4000440 300 Series Stainless Steel Al Aly 7075 T7351 per AMS QQ Stow End Plate 4000491 A 250 12 Al Aly 7075 T7351 per AMS QQ Deploy End Plate 4000492 A 250 12 Limit Switches Proprietary Valox 420 Phenolic SST Silver Link Plug 4000443 Viton Rubber Linear Way Proprietary 300 amp 400 s Stainless Angular Contact Bearing 400 Series Stainless Assorted Shims Stainless Steel Steel Wire Cu coated Silver w PTFE Spring Plunger 300 Series Stainless amp Delrin Al 6061 T6 per AMS QQ A 200 8 Ring Roller 4000398 or 225 8 Leaf Shear Pin 18 8 Stainless Steel Separation Spring 4000307 300 Series Stainless amp Delrin Al Aly 6
107. r criteria to determine if a strength test is required 6 Peak load target is 102 5 to ensure that 100 requirement is reached Load Application Pre test Analysis Load Application 6 Max Line Max Yig Or Zip Load Load Case Load Iby bott Line Load Ib bolt Step x Load Case 1 Load Case 2 Axial 51690 i Derived by Derived by Increment Derived by Derived by customer customer Fas 6 customer customer requirement and requirement and REUS AB requirement requirement Lightband Lightband inb ang Lightband and Lightband diameter damele Increment Mvis 1176 diameter diameter Allowable Ib bolt 1 880 Increment Mz s in lby Max Actual Ibi bott 102 5 Increment Peak Load Margin Derived Derived Decrement Duratoin s Max Allowable oe d Margin Allowable Max Actual 1 Decrement Decremen Functional test following all load cases Deflection Gage Placement Decremen Both Figure 18 14 Example of custom strength test requirements performed as quasi static loading 30 July 2014 www planetarysys com Page 75 of 88 2000785F MLB User Manual Planetary Systems Corporation 18 2 2 Shock Test Location PSC Objective Prove that the test item can operate nominally after being exposed to required shock profiles Test Description Then the test item will be exposed to the required shock profiles Upon completion of shock exposure
108. random vibration profiles are applied to the test item in the specified directions for the specified durations 2 The test item separates nominally after being exposed to all random vibration profiles 3 The test item is inspected IAW PSC Document 2001066 MLB Inspection Report upon completion of vibration exposure 4 All attendees of the PSC internal Test Complete Review TCR approve the test plan and results In a separation springs elongate at least 0 7 inches in an initiation springs elongate 0 0 inches Control bandwidths may be combined for tolerance evaluation purposes If additional accelerometers are added during test they shall follow the same naming convention wherein C signifies control and R signifies response Narrow Bandwith Exceedance tolerance is the maximum width that a control signal may exceed the control tolerance and still be considered acceptable Notes ww 1 e 3 4 Test Facility Data Transfer Requirements Test Facility shall provide the following data Sine Sweeps Tabulated data and plots of the FRF Magnitude and Phase Plots shall overlay pre and post sweeps Random Tabulated data and plots of the PSD profiles Random Vibration Profile Lea AINE ode AREA o Ge 20 0039 o 5 39 8 35 80 0000 40 00 612 78 200 78 13 60 n 100 Random Vibration Tolerances Random Vibration Upper Ctrl Limit Li
109. re tests Lightbands have cumulatively been operated more than 2 300 times during testing and flight operations Therefore the probability of successful Lightband separation is greater than 99 8 with a confidence interval of 95 As of the revision date of this document the Lightband has operated successfully more than 45 times in spaceflight There have been no failures to operate in spaceflight Prior to spaceflight each Lightband is separated approximately 12 17 times to verify operability These operations are part of acceptance test programs conducted by PSC As shown in Table 10 2 the Lightband allows the user to verify operation multiple times before in flight separation SSS Fairing Sep System Pyrotechnic Sep System Motorized Lightband Typical quantity of separations 12 17 on flight unit Table 10 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
110. rn 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 Separation Switch es a have changed state P P Upper EMI Gasket 4 2 Shield NO NC Lower attachment Optional metal Shield 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 10 3 Ohm 2 The metal shell conducts to the Lightband via conductive surface treatments 3 The limit switches on the Motor Bracket Assembly automatically prevent motor stall prior to end oftravel Motor Bracket Assembly 4 Required to assure electrical continuity initiates from Upper to Lower Ring Retained by Limit switches 5 The conductive path to adjoining vehicle is have changed via structural 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 7 1 Lightband Schematic 12 The DB 9 connector and the Motor cases are electrically grounded to the
111. ructure and vice versa PSC offers consultation on design of adjoining structures to customers Figure 6 17 Structures with optimal flange design Moment arms in the flange are minimal maximizing stiffness and strength 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 30 July 2014 www planetarysys com Page 22 of 88 2000785F MLB User Manual Planetary Systems Corporation As noted in Table 5 1 there are two sets of required flatness for adjoining structure 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 6 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 shape C Channel shape Figure 6 18 Example of stiff and flexible adjoining structures 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 choi
112. s those of International Space Station payloads 30 July 2014 www planetarysys com Page 10 of 88 2000785F MLB User Manual Planetary Systems Corporation 4 Lightband Flight History No Lightband has ever failed to separate on orbit To date the Lightband has operated successfully in flight more than 45 times See the flight heritage section of PSC s website for the most up to date list http www planetarysystemscorp com The Lightband has been used on the following launch vehicles e Antares Athena Atlas V Delta Il Delta IV Delta IV Heavy Falcon 1 Falcon 9 Minotaur Minotaur IV Minotaur V Pegasus XL Space Shuttle Vega Figure 4 1 A Lightband installed on the TacSat 2 mission 30 July 2014 www planetarysys com Page 11 of 88 2000785F MLB User Manual Planetary Systems Corporation 5 Lightband Capabilities and Dimensions Parameter see Bee Value Section 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 NENNEN gt 2 Stay Out Dimensions 0 02 in 1 2 o cis c c E a Mass 5 Ibm Upper Assembly 0 78 1 15 1 27 1 47 1 83 1 99 2 36 2 42 3 61 4 51 B Lower Assembly 2 50 3 47 3 76 4 32 5 05 5 25 6 08 6 53 8 77 10 57 3 3 28 4 62 5 03 5 79 6 88 7 24 8 44 8 95 12 38 15 08 1 09 1 07 1 07 1 07 1 07 1 07 1 07 1 07 1 07 1 07 1 11 1 08 1 06
113. 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 ESL PAYLOAD OPERATIONS 4 Figure 14 4 PSC engineers perform a vertical integration CAPE ICU I 30 July 2014 www planetarysys com Page 58 of 88 2000785F MLB User Manual Planetary Systems Corporation 15 Selecting a Lightband There are many determinations that must be made when a customer is selecting a Lightband to purchase This section outlines the process and choices Any Lightband that deviates from requirements defined in this document e g requires custom features additional testing different procedures or different compliance documents it is considered a Custom Lightband Prospective users should be aware that the cost and schedule of Custom Lightbands is often substantially greater than the Standard Lightband presented in this document See Figure 15 2 Part 1 Requirement Definition or Revision Read Lightband Users Manual PSC and customer determine all details of all customization PSC document 2000785 Custom features GSE special tests or test levels special inspections etc C Internal Pr Pur ads Choose Standard IAW PSC PSC Internal Product Build Specification document 20D00785 GSA Cust gt Assembly drawings of custom test item s Schedule or Custom ustom SOW SCD EDVR Test values limi
114. stems 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 tests 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
115. steners Figure 6 25 Updated Section 6 3 formerly Deleted because it was superseded by Section 7 10 Figure 7 2 Updated to graphic from 4000697B Section 8 3 Added absorptivity and emissivity ranges for hard anodize Figure 9 5 Added a legend Section 10 Added step 15 1 14 and Table 15 2 Section 10 Added comment regarding not for flight marking on EDUS in step 15 1 14 Figure 15 1 Updated to reflect current standard tests and number of seps Figure 17 2 Added Table 18 1 Changed number of TVac separations from 1 to 2 Figure 18 1 Updated with more recent test photo Figure 18 4 Updated with more recent test photo Section 18 1 2 Updated with latest test standards Section 18 1 3 Updated with latest test standards Figure 18 2 Updated Figure 18 9 Updated Figure 18 16 Added Section 20 Updated with latest procedure from 2001066B Section 21 Added reference to document 2002653 Section 22 Added reduced head diameter fasteners Section 23 Added Table 24 1 Updated photo of hex standoff Table 24 1 Added row regarding customer unpacking F 30 Jul 15 AZ WH General changed order of sections Cover Page Updated graphic Section 2 Removed PSC Team photo Removed old photos Section 3 Added item regarding ISS Section 4 Added list of launch vehicles Section 6 4 Corrected initiation time Section 6 6 Added additional explanation consolidated stiffness figures Section 6 15 Changed title Combined with section on Re
116. t schedule 16 2 Standard Delivery Schedule Standard Lightbands are typically delivered in 7 months ARO Some Lightbands can be delivered as fast as 4 months after receiving order however the price is higher Months Part Fabrication Fabrication Assembly e Test Readiness Review TRR XT Acceptance Testing opo Eo KX poppe cd _ _ Table 16 2 Standard Lightband schedule 16 3 Expedited 15 Inch Diameter Delivery Schedule PSC often carries 15 inch diameter Lightbands in stock If available these can be delivered in 1 to 2 months or less at a potentially reduced cost Contact PSC for more information and availability Time after receipt of order ARO Months Test Readiness Review TRR DOLES Acceptance Testing Table 16 3 MLB15 expedited schedule 16 4 Custom Lightband Schedule Whenever a Lightband deviates from requirements defined in this document e g requires custom features additional testing different procedures or different compliance documents it is by definition a Custom Lightband Prospective users should be aware that the cost and schedule of custom Lightbands is often substantially greater than the standard Lightband presented in this document Table 16 4 outlines a typical custom Lightband program ee Preferred Assembly drawings All test procedures Cost plus fixed Custom tooling design and dwgs fee or time and Manufacturing and test schedu
117. the Separation Switch plunger if D attached compress and elongate 0 280 0 040 inches Do the Separation Connector Pins if Choose an item attached have visually uniform free pin cc heights z 9 Does the Separation Switch plunger if Choose an item 11 attached compress and elongate 0 280 0 040 inches Lee 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 20 1 Standard inspection of Lightband 33 Excerpted from PSC document 2001066C 30 July 2014 www planetarysys com Page 81 of 88 2000785F MkII MLB User Manual Planetary Systems Corporation 21 Lightband Testing and Procedures Performed by Customer Customers often complete some of these tests and procedures after receiving the Lightband Note Lightband training is not optional See Section 23 Test or procedure Objective Remarks and cautions Learn how to operate Lightband and Can be performed with a PSC training Receive Lightband training from PSC uncover unexpected potential integration Lightband or the customer s flight unit difficulties Default location is PSC s facility Fit check to adjoining structures check to Fit check to adjoining structures structures Verify bolt patterns and clocking bolt patterns and clocking Verify bolt patterns and clocking efe re eene attached Will the Lightband
118. ts and success criteria for testing Standard Contract exceptions Sub system configuration springs switches etc connectors etc Signed Contract or revision Requirements Verification Matrix Program schedule Typically PSC s work in this dashed box is cost reimbursement basis PSC Internal Product Build Specification Test item s description Test plans Requirements verification matrix RVM Reperform if customer revises source documents Part 2 Execution of Requirements Procurement and Assembly i 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 1 amp Separation Reliability 5 10 Test Complete Review TCR Vibration Thermal Vacuum Separation Reliability Legend X Typical number of separation tests End Data Package EIDP test plans production log RYM and certification PSC quality engineer Lightband Training At PSC or at customer facility for additional cost Customer representative s Figure 15 1 Lightband selection and production process 30 July 2014 www planetarysys com Page 59 of 88 2000785F MLB User Manual Planetary Syst
119. ures allow access to 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 Transition Ring PSC Part 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 30 July 2014 www planetarysys com Page 83 of 88 2000785F MLB User Manual Lightband Test Rack Alignment pins Lightband Compression Tool PSC Part Number 4000637 Lightband Stiffness Simulator Crane Compliance Sling PSC Part Number 2002215 Reduced head diameter fasteners 30 July 2014 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 programs Records each motor s 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 Overcome the Separation Spring force when the payload is integrated This NO must be can substantially improve the ava
120. urred 15 1 9 Determine Separation Connector quantity As with Separation Switches fewer Separation Connectors allow for a simpler harness At least one Separation Connector is required to ensure conductivity through the Lightband because the Upper Ring is anodized By default PSC can include two Separation Connectors in the price of every Lightband If more than two Separation Connectors are required an additional cost is typically incurred 15 1 10 Determine Roll Bracket quantity Lightband will be classified as Custom Sometimes customers require a rotation rate about the space vehicle s thrust axis following separation Lightbands can produce roll rates up to approximately 10 degrees per second via installation of proprietary Roll Bracket Assemblies During separation the assemblies rollers contact each other inducing a roll rate about the axis The Roll Bracket Assembly mounts 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 Roll Brackets are not standard accessories and therefore their inclusion will classify a Lightband as custom Customers should contact PSC if interested 15 1 11 Determine Lightband Compression Tool quantity Lightband will be classified as Custom If the mass of the payload is less than total Separation Spring force a means to compress the Lightband before stowing is r
121. utive times with all requirements being met Do nat alter configuration Post Test Analysis 9 Analysis Predict flight Av amp rotation rates w test data amp inputs ption al for Post Test Customer Analysis of test scope i 4 RN 10 Advanced Analysis out of test I i scope Customer can correlate 12 DOF model orbit predictions beyond the measuring capability of this test fixture T to results and create higher fidelity on l Figure 18 11 Nominal separation reliability test flow 30 July 2014 www planetarysys com Page 73 of 88 2000785F MLB User Manual 18 2 Custom Acceptance Tests Planetary Systems Corporation The following acceptance tests are not standard and are not performed for all flight Lightbands Criteria that determine the need for these tests are stated herein PSC reserves the right to perform these tests on any flight Lightband if desired Any Lightband that requires any of these tests shall be considered custom Custom Lightband incur additional cost and schedule duration over Standard Lightbands 18 2 1 Strength Test Location PSC or Qualified Vibration Test Facility in DC metro area Objective Verify strength of the Lightband Test Fixture PSC Strength Test Fixture or software controlled vibration table Test Method Quasi static loading or sine burst to be selected by PSC based on engineering judgement Test Description During this
122. ze 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 This inspection shall be deemed successful if all of the responses shown in Table 20 1 are yes PSC reserves the right to pass a test item if two PSC engineers and either the Chief Engineer or President determine that a no inspection point is non detrimental to the future operation of the Lightband PSC also reserves the right to fail a test item even if the answers are all yes given the same criteria Inspections are not limited to the items in Table 20 1 and additional items may be added at the inspector s discretion QA Date amp Tech Item Description Date amp Initials 2 Initials Are all accessible fasteners tight can only Choose an item be loosened with tools n Is the staking on accessible fasteners not Choose an item delaminated by more than 25 of any accessible 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 2 heights rev C only and protrude past the profile of the Upper Housing Does

2000785 Rev D User`s Manual for Mark II Lightband

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