Harbinger 3U CubeSat: Communications Subsystem

Project Overview

This Harbinger 3U CubeSat Communications Capstone Project presents the Design, Implementation, and Manufacturing of an Autonomous Earth-Based Uplink/Downlink Station with a Complementary Quad-Dipole RF Module to support Reliable Satellite Communication. The Combination of these Systems Aim to Advance the Continuous Environmental IR Monitoring of Water Resources in the State of Utah that may Not be Visible from the Ground.

Goals

• Autonomously Track and Establish Communication with Orbital Satellites.
• Integrate the Earth Station seamlessly with Utah Tech’s Infrastructure to allow for Remote Access.
• Ensure the Final Product is Easy to Use, Intuitive for Demonstrations, and an Effective Educational Tool.
• Manufacture all Componenets In-House for the RF Orbital Module to Ensure Tight Tolerances, High Reliability, and Low Budget.

Key Contributions & Responsibilities

• Contributed to both Antenna Module & Earth Station Design with Integration and Manufacturing.
• Ensured Compliance with FCC Regulations and Safety Guidelines.
• Collaborated with a Multidisciplinary Team to Mechanically Optimize Satellite Functionality.

Skills

• Mechanical Engineering – Small Satellite Mechanical Design
• Manufacturing – Antenna & Earth Station Fabrication with Tight Tolerances and Efficient Techniques
• Systems Engineering & Integration – Combining Mechanical Components with Electrical Systems

Challenges

• Given a Strict Budget of $500 for Antenna Module & $5000 for the Earth Station.
• Had to Ensure that the Quad-Dipole Antennas would Deploy.
• Needed to make sure that the Dipoles were the Correct Material to withstand the Conditions in Space
• Prove that the Antenna Module was Robust during the Workmanship Vibration Test
• Ensure that extreme weather would Not Collapse the Earth Station ontop of the Building we were installing on.

Outcome

• Solved Budget Issue on the Antenna Module by Manufacturing All Mechanical Components in-house using the DMG Mori Duravertical 5100 CNC Machine, along with the LeBlond Lathe, and the Waterjet.
• Found a Solution to the Budget Issue on the Earth Station by using Standardized Equipment that had Seemless Integration.
• To Ensure Dipole Deployment in Space, I decided to go with a Dual Redundant Resistor Fishing Line Burning Mechanism. This Allowed for a Parallel System to be Created to Reduce Failure if one of the Resistors fails to Burning the Fishing Line.
• Through Extensive Research and Testing with Liquid Nitrogen, Found Tempered Spring Steel from inside a Tape Measure to be the Solution to withstand Conditions from Space while still Acting as a Coiled Mechanism for Deployment.
• Ensured to Use Loctite 242 (Found in NASA Technical Reports Server with Testing on Liquid Locking Compounds) on all the Fasteners connecting the Components to the CubeSat Structure, while using Flex-Top Locknuts on Through Hole Fasteners on the PCB.
• For the Earth Station, I was Tasked with Proving that 100+ MPH Winds would not topple the Earth Station Structure we Have Mounted ontop of a Building at the University, to do so I used ANSYS Workbench Static Structural with the Proper 3D CAD Drawing, Materials with Properties, Fixed or Mounted Points, Fastener Connection Points, Fine Meshing, and the Distributed Load. The Data Provided showed that the Deformation would only be about .2mm which would Not Cause Any Fracturing or Permanent Deforming.