A low cost general purpose mini-satellite bus is being designed to support a wide variety of small scientific and commercial payloads. The design incorporates several innovative concepts intended to reduce construction, launch and operational costs. The design is compatible with the new NASA extended Get-Away-Special (GAS) canister and several small low-cost expendable launch vehicles. The satellite is 19 inches in diameter, 35 inches long and weighs approximately 270 Ibs. The satellite bus provides telemetry, attitude control, orbital boost/station keeping, electrical power, microprocessor and data storage for up to 50 Ibs. of user payload . The hydrazinc propulsion system provides up to 2600 ft/sec delta-V capability. The availability of on-board propulsion reduces launcher orbital insertion accuracy requirements, provides for stationkeeping and is sufficient to allow the satellite to independently achieve 800 nm circular or 2200 nm elliptic orbits from an initial 135 nm orbit. The design stresses simplicity, ingenuity, and utilization of previously proven and high quality commercial components. Manufacturing costs are reduced by  using simple design practices and simplified test procedures. Total cost for the satellite is projected to be less than $1.5 million. Orion will be ready for launch in 1990

Mosier, Marty R.

Panholzer, Rudolf

English

Embry-Riddle Aeronautical University

The Space Congress® Proceedings 1988 (25th) Heritage - Dedication - Vision Apr 1st, 8:00 AM Orion: Design of a Small, General Purpose, Low Earth Orbit Satellite Bus Marty R. Mosier Naval Postgraduate School Monterey, California Rudolf Panholzer Naval Postgraduate School Monterey, California Follow this and additional works at: https://commons.erau.edu/space-congress-proceedings Scholarly Commons Citation Mosier, Marty R. and Panholzer, Rudolf, "Orion: Design of a Small, General Purpose, Low Earth Orbit Satellite Bus" (1988). The Space Congress® Proceedings. 9. https://commons.erau.edu/space-congress-proceedings/proceedings-1988-25th/session-11/9 This Event is brought to you for free and open access by the Conferences at Scholarly Commons. It has been accepted for inclusion in The Space Congress® Proceedings by an authorized administrator of Scholarly Commons. For more information, please contact commons@erau.edu. ORION: A Small, Full Capability, General Purpose, Low Earth Orbit Satellite BusA. E. Fuhs* M. R. Hosier** S. Michael***Naval Postgraduate SchoolSpace Systems Academic GroupMonterey, CaliforniaABSTRACTA low cost general purpose satellite bus has been designed to support a wide variety of small scientific and commercial payloads. The design provides a number of launch options, including the new NASA extended Get- Away-Special * (GAS) canister and several small expendable launch vehicles. The satellite is 48 cm. (19 in,) in diameter, 89 cm. (35 in.) high and weighs approximately 123 kg. (270 Ibs.). The satellite bus provides telemetry, attitude control, orbital boost/station keeping, electrical power, microprocessor and data storage for up to 23 kg. (50 Ibs.) of user payload. The satellite. has a hydrazine propulsion system, with up to 123 m/s (2600 ft/s) delta-V capability. On-board propulsion reduces launcher orbital insertion accuracy requirements and allows the satellite to independently achieve 1480 km. (300 nm. } circular or 4070 km, (2200 nm.) elliptic orbits from an initial orbit of 250 km. (135 nm.).Chief Scientist, Orbital Sciences Corporation; Distinguished Professor (Emeritus); formerly Chairman, Space Systems Academic Group; Immediate Past President and Fellow, AIAA.Staff Engineer, Space Systems Academic Group.Assistant Professor, Electrical & Computer Engineering Department, Naval Postgraduate School.The design stresses simplicity and utilization of previously proven components. Manufacturing costs are reduced by using high quality commercial components, good design practices and simplified test procedures. Total cost for the satellite is projected to be approximately $1.5 million.BACKGROUNDThe mission of the Naval Postgraduate School, Space Systems Academic Group is to educate and prepare military officers to assume positions of responsibility in the specification, design and operation of military space assets. Flight experiments are considered an essential part of the educational program. The complexity and thoroughness of design required in a satellite development program offers an excellent opportunity to reinforce and expand upon students academic education. Exposure to the. many interrelated and complex aspects of space missions, through constructive hands on projects such as ORION, broaden the students education and provide insight in many ways that traditional academic approaches can not. This perspective makes the students better military officers and better prepares them for future space related assignments.INTRODUCTIONThis nation's space program is caught in an upward cost spiral. Spacecraft have historically been designed for each application. The design and11-39optimization of satellites for specific missions, while achieving an optimum design, does not allow the economies of scale available in a continuous production environment to be realized. Limited budgets, high costs and long development times result in limited flight opportunities. Limited flight opportunities and long development times foster a "reliability at any cost" approach which further serves to increase program costs. As a result, satellites have become more and more complex, larger and heavier. The requirement to launch larger and heavier satellites, combined with the apparent economies of scale in launch vehicle costs, based on a myopic dollars per pound on orbit criteria, has resulted in an emphasis on the development of ever larger and more complex launch vehicles. Small innovative payloads and experiments, which historically have been the source of many major scientific discoveries (such as the. satellite that led to the discovery of the Van Alien belt), have gotten lost in the dust of this cost spiral.The ORION concept is an outgrowth of a belief that the spiraling costs and focus on "traditional" custom spacecraft development has placed access to space beyond the reach of most small users and experimenters. A broad approach is needed, which includes low cost satellites and low cost launch alternatives. A means is needed to provide economical access for small innovative payloads on a quick reaction basis. The choices available to experimenters and other low budget users have typically been limited to flying as a secondary payload on larger satellites or taking advantage of the shuttle Get-Away- Special (GAS) program. Flight opportunities as a secondary payload on larger satellites are limited and provide the user with little or no orbit and attitude flexibility. The shuttle Get-Away-Special program has provided a means of economical access to space, but flight opportunities are limited. Development and availabilityof low-cost generic spacecraft and low cost launch vehicles is essential 57 the realm of low earth orbit is ^ be opened to a wider audience of spacp users. Considerable interest has been generated in small low cost satellit** (Lightsats) by a current DARPA program to develop low cost space systems. ( Ref - 1) This program offers significant opportunities for commercial and civilian applications (Ref. 2) Low cost satellites provide new opportunities for space-based research, advancement of space technology, communications, and commercial activities which are presently available only to a select group of government and industrial firms. (Ref. 3)DESIGN CONCEPTInterest in small, low cost satellites has increased as a result of the Space Shuttle GAS program and the approval by NASA to deploy "free-flyers" from GAS canisters. (Ref. 4) The ejection concept has been demonstrated by the successful launch of NUSAT in 1984 and GLOMR in 1985. (Ref. 5) Both satellites used the standard NASA GAS canister and a launch mechanism designed to fit inside the canister. While proving the viability of launching small satellites from GAS canisters, the available satellite volume using the original configuration was too small to allow the satellites to have propulsion or attitude control capability. Recently the USAF has funded the development of an extended GAS canister with an improved launch mechanism in the base, Figure 1 compares the available satellite volume of the new design with the canister and launch mechanism used for NUSAT and GLOMR. The use of the USAF extended GAS canister provides sufficient volume to allow the development of a small satellite with propulsion and attitude control capability, (Ref. 6)11-40While satellite launch using the space shuttle provides an economical means of access to space the number of launch opportunities that will be available using GAS canisters on the redesigned Space shuttle is in doubt.CURRENT DESIGNEXTENDED CONFIGURATIONFigure 1Volume Comparison of GAS Canister ConfigurationsThe DARPA Lightsat program recognizes the need for lower cost launch alternatives and includes an emphasis on the development of lightweight lower cost launch alternatives. (Ref. 1)DESIGN OBJECTIVESThe Naval Postgraduate School general purpose mini-satellite, ORION, was designed with four basic objectives: (Ref. 7)1. Support a payload weight and volume of at least 23 kg. (50 Ibs.) and 0.06 cu meters (2 cu. ft.).2. Provide maximum launch option flexibility.3. Provide full satellite support capability such as attitude control, propulsion, continuous electrical power, computer and data storage, and telemetry.4. Minimize manufacturing costs.The first objective is based on surveys conducted by Aerospace Corporation (Ref. 8) and discussions with potential users during 1984-1986. The concept of providing a general purpose vehicle with specified capabilities might require the user to modify experiment design but flexibility is significantly better than that available as a secondary payload or Shuttle cargo bay experiment. In some cases, the satellite might provide capabilities in excess of that required for a particular mission, however, economies of scale should reduce total cost below that required to design and produce a lesser capability custom satellite.Minimizing launch costs and maximizing launch opportunities means that the design must be compatible with as many launch alternatives as possible. To this end, the Shuttle extended GAS canister was selected as a configuration baseline for the ORION. Figure 2 presents a cross sectional view of the ORION satellite. This configuration is also compatible with a wide variety of existing and proposed small launch vehicles.To support a wide variety of potential users the satellite must provide all typical satellite support functions. These functions include orbital boost/station keeping, attitude control, electrical power, computer and data storage, and telemetry. With these services provided by the satellite bus, the experimenter is free to focus attention and resources on experiment design.The satellite must be simple and economical to manufacture. By using currently available components and creative design approaches a cost goal for satellite components of $1.5 million should be achievable. The design also focuses on simple manufacturing techniques so that potential users can fabricate the satellite with minimum requirements for tooling and manufacturing equipment.11-41PAYLOAD MODULEELECTRONICS MODULE & SENSORSBATTERYSPINCONTROLTHRUSTERPROPELLANT TANKVALVES& CONTROLSPRESSURANTPRECESSION THRUSTERSPRIMARY THRUSTERFigure 2 .ORION Internal LayoutVEHICLE— 120 —• — 19 "— ir jij-JkJOnirr——— • ———— » 135'1J "Figure 3 ORION Structural DesignTable 2 provides a summary of the ORION satellite capabilities.Table 2 SUMMARY OF ORION SPECIFICATIONSVEHICLE- 19 inch diameter; 35 inches tall; 5.7 cubic feet total volume- Total weight of 270 pounds.PAYLOAD- 1.5 to 2.5 cubic feet- 50 to 100 poundsPROPULSION- Monopropellant hydrazine- Total impulse of 15,720 Ibf- sec; 2625 ft/sec delta-V- Circular orbits to 800 nm. (From 135 nm)- Elliptical orbits to 2200 nm. apogeeELECTRICAL POWER- Silicon solar cells attached to cylindrical surface- 50 watts total power; 15 watts continuous power to payload- Common power supply with regulated voltage bus- Redundant Ni-Cad batteries; 150 Watt-hour capacityTELEMETRY- Several telemetry options - SGLS; UHF; S-Band- Two antennas provide omni­ directional coverageMICROPROCESSOR AND DATA STORAGE- General purpose 16 bit microprocessor- Non-volatile bubble memory data recorder- Up to 12 megabytes using NFS design- Data rates up to 2.0 Mega-bits per second11-42S-BANDTELEMETRYANTENNABOOH IN STOWED POSITIONLONGERONSPIN 1HRUSTERSTOWED POSITIONSUN .SENSORHYORAZINE TANKPYROTECHNIC VALVEPRESSURANT TANKLONGERONBATTERYS-BAND TELEMETRY- RECEIVERAXIAL THRUSTERBASE PLATECOMPUTERDATASTORAGEANDCONTROLLERSPIN THRUSTERHYDRAZINE TANKPRESSURANT •TANKEARTH SENSORRETAINING LUG. ONE OF 8Figure 4 ORION Mock-Up Internal DetailsDESIGN FEATURES,Stmctural.....Des.ignThe satellite is cylindrical, measuring 48 cm. (19 in.) in diameter and 89 cm. (35 in.) in length. The structural design of ORION stresses simplicity and ease of manufacture. It is anticipated that most of the structural elements will be made of aluminum with the use of composites for critical elements. The basic structure is shown in Figures 3, 4 and 5 - The design consists of four longerons and several circular equipment mounting plates. Structural rigidity is increased by the external s^in quarter panels which are also used to hold the silicon solar cells. Launch loads are transmitted to the vehicle via the eight retaining lugs 011 the adapter ring attached to theFigure 5 ORION Mock-Up Internal Detailssatellite base. Satellite components are mounted to the circular mounting plates which may be moved axially to change the volumes available for the various components and to insure proper location of the center of gravity.Propulsion permits changes in orbit and reduces launch vehicle orbital insertion accuracy requirements. Figure 6 shows the operating envelope of the ORION satellite bus, assuming orbital insertion at 135 nm. The ability to change orbital parameters and control the -satellite's attitude are critical elements in the ORION design. This capability gives the user the option of placing the payload in the optimum orbit and maintaining the optimum orientation for a11-43particular mission. The hydrazine tank contains sufficient hydrazine to allow the satellite to achieve circular orbits of up to 1400 km. (800 nm.) and elliptical orbits with an apogee of up to 4070 km. (2200 nm.) starting from an initial nominal orbit of 250 km. (135 nm.) .The satellite is spin stabilized using hydrazine thrusters. Stability about the cylindrical axis is provided by simple folding booms, with friction extension dampers. Innovative control techniques are being investigated for three-axis dual-spin configuration. Boom radius of 80 inches can be easily achieved by simple three section folding booms and provides a ratio of spin -to transverse moment of inertia of 1.18. The three-axis configuration should provide pointing accuracies to better than +/- 1.0 degrees.CAPABILITY GAP2,50001,000MBIT500 --•100 --GUM: lUSff—\Lwtf•^SPARTANM 100 150 200 2S TOTAL MVLOAD «f«tFigure 6 ORION Operating Envelope_4__300Spacecraft power is provided by silicon solar cells mounted to the exterior surfaces of the skin quarter- panels » This configuration provided 50 watts of power when the satellite is oriented normal to the sun at the beginning of life. Up to fifteen (15)watts of continuous electrical is provided to the paylbad. batteries are used to SUpport continuous operation. ^urtfflmmtftLmiJi^ORION is designed with a focus on autonomous operation , including experiment control , attitude determination and control and all housekeeping functions. Qn-board data storage is also provided. The Naval Postgraduate School has developed a non-volatile magnetic bubble memory data recorder for this purpose. The currently planned data recorder provides 12 mega-bytes of storage capability with peak data rates of over 2 mega-bits per second. (Ref. 9)Telemetry requirements are strongly influenced by mission specific considerations. VHF, USH and S-band telemetry may be used depending on mission requirements,ORION APPLICATIONSApplications for the ORION mini- satellite include a wide range of space science missions. One mission uses ORION'S propulsion capability to place the satellite in a highly elliptical orbit into the lower van Alien belt. The satellite has been proposed to .support the Tethered Satellite Experiment (TSS-1) and provides a means of measuring near field interactions between a long tether and the surrounding fields. Two ORION type satellites, flying in formation, could be used to develop a worldwide geopotential model accurate to 10 cm. (Ref. 10) An ORION, could be instrumented as an all-sky heliospheric Imager (ASHI). By recording the brightness of scattered light from electrons- in the interplanetary medium , the imager coul d obs e r ve di s turbance s • anywhere within one astronomical unit. 11)11*44CONCLUSIONSThe ORION concept has attained a level of design maturity that confirms that the vehicle can be built for component costs of less than $1.5 million. The project has achieved its primary purpose at the Naval Postgraduate School in stimulating creative thinking on the parts of the students and faculty relative to low cost satellite alternatives.REFERENCES1. DARPA/AIAA Meeting on Lightweight Satellite Systems. August 4-6 , 1987, Monterey, CA.2. Alien E. Fuhs and John Sanders. "Lightsats . . . Moving from Fringes to the Mainstream, Mmspa£.&.,... Affl.SX.ica, October 1987.3. Richard G. O'Lone. "U.S. PlanningNew Emphasis on Lightweight SatelliteSystems" , Ay.i.a.tio.^l^M,QlQ..gy/ August 10, 1987, pages 22-23.4. A. W. Boyd and A. E. Fuhs.urp.o.s..e,..........S..ja.,t..ell..i.t^, AIAA 87-0584, 1987.5. Tina D. Thompson, Editor, I.R.W §M££.,iQg..,. 1984-1985, Volume 21, pages 22 and 30.8. Aerospace Corporation. Experiment Planning Directorate, Conc ep. tua1D.aai.gji_^^Program........ Standard ....... S a t el 1 it e . May 30,1975.9. A. W. Boyd, et.al. "Autonomous Measurement of Space Shuttle Payload Bay Acoustics During Launch." Naval E.e..5..e.ar..Q.h.......,.Re.vl..^.w.^, One, 1987 , volumeXXXIX, Pages 9-17.10. V. L. Pisacane, S. M. Yionoulis, A. Eisner, and H. D. Black. .SAGE....... ....... A.!!^ja,.,.M^^.£he..........G.rayity.........Model , Presented at theAmerican Geophysical Union Meeting, Fall 1984.11. John Hopkins University, Applied Physics Laboratory. All-Sky He 1 i o sph e r. i. c.........!.m..a.ger. ............[.AS.HI.)....,..... ..In t erf. ace.C.Qn£r.Q.l.,...D.Q..c.um^.n.'t. JHU/APL , SDO 8416,April 1987.6. A. w. Boyd.igm^.Satellite. MSEE Thesis, Naval Postgraduate School, Monterey, CA, September 1987.7- A. E. Fuhs, A. W. Boyd, and M. R.M°sier. QRIQS.:.........,..A........General.......... Purpose.,.L.Q.w-.C.Q.s.t. ,..,.... Light.s,at . Proceedings ofDARPA/AIAA Meeting on Lightweight Satellite Systems, Published by AIAA,1987.11-45

Orion: Design of a Small, General Purpose, Low Earth Orbit Satellite Bus

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Orion: Design of a Small, General Purpose, Low Earth Orbit Satellite Bus

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