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Standard Design Process for Spacecraft

The document outlines the design process for spacecraft, which involves deriving design specifications based on criteria and requirements, developing and testing models, and conducting reviews. Key aspects of the process include: 1) Deriving initial design specifications based on functioning, loads, environments, materials, and other factors. 2) Developing a design and test plan, defining work packages for activities, inputs, and outputs. 3) Further elaborating the design through studies, simulations, tradeoffs, and testing models like structural, thermal, electrical, and qualification models. 4) Conducting design reviews like a preliminary design review before test model production and a critical design review before qualification and flight model production.

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Cristian Andrei
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18 views3 pages

Standard Design Process for Spacecraft

The document outlines the design process for spacecraft, which involves deriving design specifications based on criteria and requirements, developing and testing models, and conducting reviews. Key aspects of the process include: 1) Deriving initial design specifications based on functioning, loads, environments, materials, and other factors. 2) Developing a design and test plan, defining work packages for activities, inputs, and outputs. 3) Further elaborating the design through studies, simulations, tradeoffs, and testing models like structural, thermal, electrical, and qualification models. 4) Conducting design reviews like a preliminary design review before test model production and a critical design review before qualification and flight model production.

Uploaded by

Cristian Andrei
Copyright
© All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
Available Formats
Download as PDF, TXT or read online on Scribd

2 Design Process

2.1 Introduction

The process of designing and developing spacecraft is characterised by the fact that
it concerns single and “one-off” time product, that have to be produced within a
given amount of time.
Requirements of the principal and subsequent testing of test models lead to the
final design. This final design is then laid down in working drawings and other
documents, all of which define the final product or flight model.

2.2 Design criteria

Any design is led by the design criteria (mass, stiffness, shape, etc.). The proposal
phase is intended to leave room for negotiations on any alterations of the design
criteria. Depending on the kind of project, it may be necessary to derive further
specifications for subsystems, such as the solar arrays, from the design criteria.

2.3 Design specification

The first step of the design process is to derive the design specification. This needs
to comply with demands concerning:
• functioning with regard to primary tasks
• mechanical loads
• environmental influences
• material properties
• weight and balance
• reliability and lifetime

5
6 2 Design Process

• safety
• exchangeability, repairs and maintenance
• manageability
• interactions
Based on the design specification, a design and development plan is worked out
and work packages are defined. A work package describes the activities to be per-
formed, the available time and the resources available. It also includes the neces-
sary input and the expected output.

2.4 Design

Based on the design and development plan, the design specifications are further
tested and elaborated on during the design process by means of design studies,
computer simulations, analyses, trade-off studies, detailed testing, as well as
designing and testing test models.
During each step of the process the level of detail is increased in such a way
that, through design drawings, the design can be finalised in production documents
(drawings, manufacturing sheets), test plans and procedures.
Testing and studying certain aspects by means of test models form an important
part of the design process. These are not complete models. In most cases the fol-
lowing will be used:
• the structural model (SM, dynamic aspects)
• the thermal model (TM, thermal behaviour in vacuum)
• the electrical model (EM, the electrical behaviour of all systems combined and
in relation to the ground testing equipment or EGSE: Electrical Ground Support
Equipment)
• the qualification model (QM, qualification of the design for production of the
flight model, FM)
For the development of attitude control systems an attitude control model is
added.
Tests on the test models may lead to changes in the design. Deviations from the
design specifications need to be approved by the client.

2.5 Design control

The design process consists of several steps in which the design is laid down in
more detail. These steps are usually concluded with a number of reviews. In most
cases these are:
2.6 Exercises 7

• a preliminary design review (PDR) for the release of the preliminary design, in
general before starting production of the test models
• a critical design review (CDR) before the release of qualification and flight
models, preferably before the start of flight model production.

2.6 Exercises

2.6.1 Design and development

Find somewhere a design and development plan of ESA and NASA spacecraft.

Common questions

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The main challenges in the spacecraft design process include ensuring the reliability and performance of one-off time products, adhering to strict design criteria, and meeting the subsequent testing requirements . These challenges are addressed through iterative design reviews, such as Preliminary Design Reviews (PDR) and Critical Design Reviews (CDR), which ensure that both preliminary and critical aspects of the design are thoroughly evaluated and validated before significant production phases commence .

Design specifications shape the development of a spacecraft by detailing the requirements concerning functionality, mechanical loads, environmental influences, and other critical factors such as weight, reliability, and safety . These specifications form the foundation for creating a comprehensive design and development plan, which encompasses all necessary activities, time frames, and resources. Consequently, they ensure that the resulting design aligns with operational and performance expectations .

Test models play a crucial role in validating various design aspects before finalizing production documents. They are utilized for assessing dynamic, thermal, electrical, and overall system qualifications under realistic conditions. Typical test models include the structural model (SM) for dynamic aspects, the thermal model (TM) for thermal behavior, the electrical model (EM) for evaluating combined system electrical behavior, and the qualification model (QM) for verifying design suitability for production .

Defining work packages in the spacecraft design and development plan is crucial as they delineate specific activities, allocate time and resources, and outline necessary inputs and expected outputs. This structured approach enhances project coordination, facilitates task accountability, and ensures a clear roadmap for achieving project milestones, ultimately leading to successful project execution within planned timelines and budgets .

Changes to spacecraft design specifications, often arising from testing insights or refined requirements, are managed through a structured approval process where any deviations or modifications must be sanctioned by the client. This ensures alignment with the original project objectives and requirements, maintaining the integrity of the design process and final product .

Ensuring the reliability and lifetime of a spacecraft requires consideration of materials used, structural integrity under various mechanical loads, robustness against environmental influences, and redundancy in critical systems. These factors, outlined in the design specifications, must integrate margin allowances and failure modes predictions to withstand operational demands across the spacecraft's mission duration .

The requirements for exchangeability, repairs, and maintenance influence spacecraft design criteria by necessitating considerations for modularity, accessibility, and ease of component swap-outs within the design. These aspects must be incorporated into the initial design criteria to ensure the spacecraft can be efficiently serviced and maintained without compromising its operational capability or safety .

The Preliminary Design Review (PDR) is critical in evaluating the completeness and feasibility of the initial design before entering the production of test models, ensuring that foundational and strategic design elements meet the project's objectives . The Critical Design Review (CDR) provides a comprehensive assessment before the release and production of qualification and flight models, confirming that the design is technically mature and ready for final production, thereby mitigating risks associated with design errors in later stages .

Environmental influences significantly impact the design and material selection for spacecraft by dictating requirements for thermal regulation, radiation shielding, and mechanical durability under space conditions. Materials must be chosen to withstand extreme temperatures, micrometeorite impacts, and potential corrosive elements, requiring robust testing and validation through environmental models to ensure longevity and operational efficacy in the harsh conditions of space .

The design proposal phase facilitates negotiation and flexibility by allowing stakeholders to discuss potential changes to initial design criteria. This phase is intended to create room for alterations that can tailor the spacecraft's design to better suit specific project requirements or to incorporate technological advancements, thus enhancing project adaptability and innovation .

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