Chapter 6 Spacecraft Design and Verification Requirements
Table of Contents
6
Spacecraft Design and Verification Requirements....................................................... 6-1
6.1
6.2
6.3
6.4
Safety Requirements........................................................................................... 6-1
6.1.1 Selection of Payload Materials ................................................................ 6-1
Design Characteristics ........................................................................................ 6-1
6.2.1 Mass Properties....................................................................................... 6-1
6.2.2 Centre of Mass Constraints ..................................................................... 6-1
6.2.3 Structural Integrity.................................................................................... 6-1
[Link] Factors of Safety........................................................................ 6-1
[Link] Dimensioning Loads .................................................................. 6-2
6.2.4 Stiffness ................................................................................................... 6-2
6.2.5 Overflux ................................................................................................... 6-3
Spacecraft Mechanical Qualification and Acceptance Tests............................... 6-3
6.3.1 Static Load Test....................................................................................... 6-3
6.3.2 Sinusoidal Vibration Test ......................................................................... 6-3
6.3.3 Random Vibration Test ............................................................................ 6-3
6.3.4 Acoustic Noise Test ................................................................................. 6-4
6.3.5 Shock Test............................................................................................... 6-4
Interface Tests..................................................................................................... 6-4
List of Figures
Figure 6-1
Typical limit load factors for initial dimensioning of secondary structures
and equipment brackets. ...............................................................................6-2
List of Tables
Table 6-1
Table 6-2
Table 6-3
Sinusoidal vibration loads..............................................................................6-3
Typical mechanical verification test matrix for qualification (Q) and
acceptance (A) of the spacecraft...................................................................6-4
Acoustic noise spectrum. ..............................................................................6-4
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Spacecraft Design
and Verification
Requirements
This chapter defines the spacecraft design
and verification requirements that have to
be taken into account in preparation of a
launch on Rockot/Breeze-KM. Any deviation from these requirements has to be
mutually agreed.
mass moment of inertia better than 10 %.
The CoM shall be specified with an accuracy of 50 mm along the launch vehicle
longitudinal axis and within a circle of 30
mm radius around the launch vehicle longitudinal axis.
For spacecraft using liquid propellant the
dynamics of the liquid shall be specified by
means of a proper sloshing model at different acceleration levels.
6.2.2
6.1
Safety Requirements
The Customer is required to design and
operate the spacecraft in accordance with
the launch site safety regulations described
in chapter 9. It must be assured by appropriate means (mechanical ground support
equipment design, operational procedures)
that constraints related to ground operations do not become design drivers for the
flight hardware.
6.1.1
Selection of Payload Materials
Properties as well as types of materials
and components used for the spacecraft
design must be based on recognised standards agreed by the launcher authority.
6.2
6.2.1
Design Characteristics
Mass Properties
The spacecraft mass properties shall be
defined according to the following accuracies to enable dynamic analyses to be
undertaken as part of the overall spacecraft to commence vehicle preliminary mission analyses. The mass shall be specified
with an accuracy of better than 2.5 %, the
Centre of Mass Constraints
The Rockot launch vehicle is capable of
supporting a large variation of the CoM
position along its X-axis. However, the
dependency of the lateral accelerations on
the CoM position may limit its position on
the X-axis.
The total displacement of the composite
CoM of the spacecraft or a combination of
multiple spacecraft and the Breeze-KM
must stay within a radius of 30 mm around
the launch vehicle longitudinal axis. This
imbalance directly affects the controllability
of the upper stage and thus the spacecraft
angular velocities at separation
6.2.3
Structural Integrity
[Link]
Factors of Safety
The minimum factors of safety to be taken
into account for structural dimensioning
are:
Yield load: j 1.1
Ultimate load: j 1.25
The factors of safety apply to combinations
of simultaneously acting mechanical and
thermal limit loads.
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Limit load factor, g
1000
100
10
0.1
10
100
Equipment mass, kg
Figure 6-1
[Link]
Typical limit load factors for initial dimensioning of secondary structures and equipment
brackets.
Dimensioning Loads
Structural dimensioning must take into
account critical combinations of simultaneously acting load types.
Generic design accelerations for spacecraft primary structure dimensioning are
compiled in chapter 5.1.2.
Secondary structures and equipment
brackets must be dimensioned taking into
account local responses to the combined
effect of simultaneously acting low frequency transient and high frequency random vibrations. Typical mass-dependent
combined load factors n are presented in
Figure 6-1 as a design guideline. For dimensioning, limit load factors have to be
applied
at equipment / unit CoM,
in the worst case spatial direction with
respect to resulting stresses and reactions.
Limit load factors cover equipment / unit
responses due to quasi-static and lowfrequency transient and random accelerations encountered during lift-off and ascent.
6.2.4
Stiffness
To avoid dynamic coupling between the
low-frequency launch vehicle and payload
modes, the payload minimum natural frequency f0 is required to be:
Lateral (Y-Z plane): f0 15 Hz
Axial (X): f0 33 Hz
Note: Resonance requirements are related
to spacecraft modes with significant effective mass of meff 70%. The minimum
natural frequency values are targets for
design, if existing spacecraft are not compliant, the given requirement can be relaxed based on CLA results. For heavy
spacecraft, additional coordination with
EUROCKOT is required to ensure that the
structural modes of the integrated space-
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craft/ adapter stack do not decrease below
critical limits.
6.2.5
Overflux
Overflux refers to disturbances of the axial
line load at the interface of the adjacent
mating structures. These local disturbances are caused by structural discontinuities such as stringers, cut-outs, etc.
Overflux requirements apply to clamp
adapters only and will be specified on a
case-by-case basis.
6.3
Spacecraft Mechanical
Qualification and Acceptance
Tests
The Customer shall demonstrate that the
spacecraft structure complies with the required design characteristics as defined in
Chapter 6.3, taking into account the environmental conditions stated in chapter 5.
Additionally, spacecraft mathematical models submitted to the launcher authority for
performance of final coupled analyses and
flight mechanics analyses must be verified
by tests.
A typical qualification/acceptance test matrix is shown in Table 6-2. The spacecraft
verification plan finally selected needs to
be approved by the launcher authority.
6.3.1
Static Load Test
On the basis of dimensioning loads given
in chapter [Link], EUROCKOT defines
critical load cases to which the spacecraft
structure will be subjected. The structure
must successfully pass static load tests up
to:
Qualification model: ultimate load (1.25
times limit loads)
Protoflight model: yield load (1.1 times
limit load)
For a realistic simulation of the load introduction, the spacecraft must be attached to
a flight representative adapter or separation system during the static test.
6.3.2
Sinusoidal Vibration Test
The inputs at the spacecraft adapter interface are shown in Table 5-2, and the test
factors in Table 6-1.
A permission for notching of sine test levels at critical resonances may be requested from EUROCKOT in order not to
exceed the spacecraft flight responses
predicted by coupled load analysis.
Test factors
Sweep rates
(one sweep per
axis)
Table 6-1
6.3.3
Acceptance
Qualification
1.25
4 oct/min
2 oct/min
Sinusoidal vibration loads.
Random Vibration Test
Random vibration test is recommended
only for small satellites of 100 kg mass or
less and for satellites with small dimensions. The vibration loads for this purpose
will be specified on a case-by-case basis,
see chapter 5.1.5.
For larger spacecraft, EUROCKOT recommends to perform an acoustic test to
accurately reflect the in-flight random environments experienced. Since the vibration
level depends on the dynamic properties of
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A permission for notching of random vibration test levels at critical resonances may
be requested from the launcher authority in
order not to exceed local responses measured during an acoustic noise test or determined by an acoustic response analysis.
the payload adapter structure, this test
should be performed with the spacecraft
attached to a flight-like payload adapter
(not hard mounted) to accurately represent
the flight configuration.
Required Tests
Static
Chap. 6.3.1
Test Hardware
Q
Prototype Philosophy:
Qualification Model
Flight Model
Protoflight Philosophy:
Protoflight Model
Sinusoidal
Chap. 6.3.2
Random
Chap. 6.3.3
X1)
X1)
X2)
Acoustic
Chap. 6.3.4
X1)
Shock
Chap. 6.3.5
X2)
1) alternatively for small satellites
2) optionally
Table 6-2
6.3.4
Typical mechanical verification test matrix for qualification (Q) and acceptance (A) of the
spacecraft.
Acoustic Noise Test
6.3.5
The acoustic noise spectrum as defined in
chapter 5.1.4 must be used as the test
input with the factors and durations of
Table 6-3 applied.
Acceptance
Test factor for
acoustic
pressure
Exposure
duration, s
Table 6-3
Qualification
Protoflight
Qualification
Per SC designers national standard
60
120
60
Acoustic noise spectrum.
The requested test duration takes into account a scatter factor significantly greater
than four.
Shock Test
Shock tests of complete spacecraft must
be conducted by firing of the planned separation system. For predicted shock response spectra, see Chapter 5.1.6.
Interface Tests
6.4
Depending on the specific mission the following set of compatibility tests may have
to be performed:
The Matchmate test, also referred to as
Fit-check test for verification of electrical and mechanical interfaces of the
spacecraft to the adapter and separation system. This test is performed
preferably with flight units and can be
combined with a functional test of the
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separation system. This test is mandatory for each mission.
If necessary, volume compatibility test
with fairing and adapter. A satellite
dummy simulating the spacecraft static
envelope will be used for this purpose
Additionally, the following test have to be
performed in case of necessity:
Thermal tests
EMC tests
Dedicated electrical interface tests
when non-standard interfaces are used
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