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Chapter 6: Integration Procedure

Building the Cube

Initial Structure Assembly

1. For this part of the integration, you will need two main “U” halves, four small L-shaped brackets, and stainless steel 5mm long M2.5 button head fasteners. Remember to remove all the tabs from the boards.

Figure 6.1: Tabs to remove from all boards

Figure 6-1

Note

It is extremely important that the button head fasteners are used in this step and NOT the pan head fasteners for the L brackets, as this will allow the solar boards to fit on top of the fasteners.

2. Loosely attach the two halves together using the four L-brackets and 5mm fasteners as shown in Figure 6.2 below. Do not over-tighten, as we will “square up” the structure later using a jig.

Figure 6.2: Small Elbow Brackets placed on structure

Figure 6-2

Warning

Make sure to ALWAYS screw in the fasteners horizontally when dealing with pre-installed pem-nuts.

3. If you happen to pop out one of the pem-nuts, secure the fasteners with locknuts, but be extra careful not to tighten them too much.

Warning

TORQUE SPEC IS 0.59 N·m (5.22 in-lb), DO NOT EXCEED THIS ON M2.5 BOLTS/FASTENERS.

Initial Bracket Mounting

1. Secure 2 battery board card brackets onto the board using M2.5x5mm pan head bolts as shown in Figure 6.3 below. Do the same for the flight controller board.

Figure 6.3: Attached board card brackets to Flight Controller Board and Battery Board

Figure 6-3

2. Flight the flight controller board to the battery board. Then angle the board diagonally with attached brackets and insert into the internal volume of the main structure.

Figure 6.4: Battery Board and Flight Controller Board on Satellite

Figure 6-4

Figure 6.5: Figure 6.4: Battery Board and Flight Controller Board on Satellite

Figure 6-5

Integrating Satellite Feet

Installing Feet Assembly

1. Use M2.5x10mm pan head fasteners, and M2.5 locknuts to install the feet.Install the feet so the feet with the switches inside should be diagonal from one another. Use Blue Loctite if this is the final satellite. 2. To install the feet on the structure, place locknuts in the small openings of the feet as shown in Figure 6.6, with the nylon side of the locknut facing towards the interior of the satellite. Press downwards on the top of the feet while also pressing them up against the side of the structure. Remember to plug them into the flight controller board!

Figure 6.6: Feet Mounted on Satellite Half

Figure 6-6

Applying Thermocouple (Optional)

1. Apply space-rated glue to the thermocouple and place it on the side of one of the two middle batteries. Make sure that the metal part of the thermocouple is touching the battery casing.

Applying Thermal Blanket (Optional)

1. Place strips of double-sided Kapton tape along the face of the batteries and press the thermal blanket down against the exposed tape. 2. Fold the ends back against the outer-facing side of the thermal blanket.

Squaring the Satellite

It’s Jig Time!

1. Place the structure into the jig as shown in figure 8.11. Slide it back and forth multiple times through the jig to square up the structure.

Note

If you cannot fit the satellite into the jig, loosen the fasteners on the structure (not including the feet) and attempt to fit it again.

Figure 6.7: Satellite in Jig, able to be screwed at the top

Figure 6-7

Figure 6.8:Satellite in Jig, able to be screwed at the bottom Figure 6-8

2. If preparing for a launch, apply Loctite. Without taking the satellite out, unscrew fasteners one at a time and secure them by dipping them in Blue Loctite and placing them back in the structure. Be careful with the fasteners that are screwed into the small L brackets.

Adding the Faces

1. Plug the faces into the flight controller board, including the Z-face and the antenna baord. Then screw them onto the faces of the cube. Wiring the Z-face before you fasten all the faces will make it easier to plug the Z-face in.

Figure 6.9: Solar Faces being added

Figure 6-9

Figure 6.10: Z-Board being added Figure 6-10

Note

You will have to remove one of the faces to program the cubesat as of now the antenna board USB-C doesn’t work. This should be in a later update.