The City College of New York

Department of Mechanical Engineering

Magnetic Hysteresis-based Passive

Attitude Control for CUNYSat-1
Mechanical Engineering 47400 Senior Design Project
Prof. Charles B. Watkins

CCNY PicoWorks
Team Leader
Dean James
Team Members
Aldi Dilo
Javier Franco
Mourad Bennis
Danishwer Khan

December 10, 2009

• Introduction
• Problem Statement and Design Specifications
• Design Concepts
• Product Architecture
• Configuration Design
• Parametric Design
• Final Design
• Analysis & Testing
• Prototype Applications
• Recommendations
• Conclusion
• Acknowledgements
CCNY PicoWorks
2 Final Presentation 12/10/2009
 Introduction- CubeSat

CalPoly’s
History Purpose
Role

CCNY PicoWorks
3 Final Presentation 12/10/2009
 Introduction- CUNYSat and CCNY
PicoWorks
CUNYSat
• University-wide Research group
• Will construct CUNYSat-1, a CubeSat-
compliant nanosatellite

CCNY PicoWorks
• CCNY ME Senior design team
• Charged with designing optimal
ADCS.

CCNY PicoWorks
4 Final Presentation 12/10/2009
• Introduction
• Problem Statement and Design Specifications
• Design Concepts
• Product Architecture
• Configuration Design
• Parametric Design
• Final Design
• Analysis & Testing
• Prototype Applications
• Recommendations
• Conclusion
• Acknowledgements
CCNY PicoWorks
5 Final Presentation 12/10/2009
 Problem Statement and Design
Specifications

• Problem Statement
– Upon separation from the launch vehicle,
CUNYSat-1 will have random orientation and spin

CCNY PicoWorks
6 Final Presentation 12/10/2009
 Problem Statement and Design
Specifications
• Design Objective
– Design an ADCS subsystem to control the
orientation of CUNYSat-1 and to stabilize its spin

CCNY PicoWorks
7 Final Presentation 12/10/2009
 Problem Statement and Design
Specifications
• Major Constraints
– 40 grams of the mass budget will be set aside for
the ADCS
– Power consumption should be minimal
– Mechanical complexity should be avoided when
possible
– Cost should be minimized where possible

CCNY PicoWorks
8 Final Presentation 12/10/2009
 Problem Statement and Design
Specifications
• Product Design Specifications
– All components of the subsystem must be fully
compliant with the latest version of the CubeSat
Design Specifications
– The subsystem may weigh no more than 40
grams
– The subsystem must be able to stabilize the
satellite

CCNY PicoWorks
9 Final Presentation 12/10/2009
• Introduction
• Problem Statement and Design Specifications
• Design Concepts
• Product Architecture
• Configuration Design
• Parametric Design
• Final Design
• Analysis & Testing
• Prototype Applications
• Recommendations
• Conclusion
• Acknowledgements
CCNY PicoWorks
10 Final Presentation 12/10/2009
 Evaluation
matrices
Active
Concepts

Passive
Concepts

Design Concepts

CCNY PicoWorks
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 Passive Design Concepts
Passive

Telescoping Wire Drum Coilable Magnetic

Boom Deployer Boom Hysteresis

CCNY PicoWorks
12 Final Presentation • 12/10/2009
 Active Design Concepts
Active

Controlled
Reaction Momentum
Torquer coils momentum
wheels wheel
gyros

CCNY PicoWorks
13 Final Presentation • 12/10/2009
 Evaluation Matrix- Passive Stabilization
Concept Cost Ease of Mechanical Power Collision Total
Manufacture/ Complexity Consumption Recovery
Acquirement

Telescoping 0 -- -- - 0 -5
Boom
Wire Drum + - - - - -3

Deployer

Coilable -- - - - -- -7

Boom

Hysteresis ++ + + + + 6
Rod

CCNY PicoWorks
14 Final Presentation 12/10/2009
 Evaluation Matrix- Active Stabilization
Concept Cost Ease of Mechanical Power Weight Total
Manufacture/ Complexity Consumption
Acquirement
Reaction 0 0 0 - 0 -1
Wheel
Momentum + 0 0 0 + 2
Wheel

Torquer Coil - + + 0 + 3

Controlled - + + + - -1
Momentum
Gyro

CCNY PicoWorks
15 Final Presentation 12/10/2009
• Introduction
• Problem Statement and Design Specifications
• Design Concepts
• Product Architecture
• Configuration Design
• Parametric Design
• Final Design
• Analysis & Testing
• Prototype Applications
• Recommendations
• Conclusion
• Acknowledgements
CCNY PicoWorks
16 Final Presentation 12/10/2009
Product Architecture: Components
Item Description

Rod- dissipates oscillation energy in

form of heat

Magnet- aligns satellite in same axis as

that of the Earth magnetosphere's field
lines

Bracket- secures magnetic materials to

satellite, ensuring transmission of
torque to satellite

CCNY PicoWorks
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 Product Architecture:
Functional Schematic

CCNY PicoWorks
18 Final Presentation 12/10/2009
 Product Architecture: Fundamental
Interactions

Item Fundamental Interaction

Magnet Torque between itself and magnetosphere
Hysteresis rod Internal magnetic domain realigned to local flux lines
Brackets transmits torque to satellite

CCNY PicoWorks
19 Final Presentation 12/10/2009
 Product Architecture:
Secondary Interactions

Item Secondary Interaction

Magnet may interfere with other electronic components on board the
satellite

Hysteresis Rod Heat transferred to satellite

Bracket Inefficient design will result in excess weight

CCNY PicoWorks
20 Final Presentation 12/10/2009
• Introduction
• Problem Statement and Design Specifications
• Design Concepts
• Product Architecture
• Configuration Design
• Parametric Design
• Final Design
• Analysis & Testing
• Prototype Applications
• Recommendations
• Conclusion
• Acknowledgements
CCNY PicoWorks
21 Final Presentation 12/10/2009
Configuration Design via CubeSim
 Config. Design- Magnetic Materials
Ratio vs. Stabilizing Time & Resolution
Magnet ratio(p/h) Transient time(min) Stab. Resolution(deg)

0.5 20 36.72
0.875 23 29.7
1 28 21.74
1.143 28 19.62
1.5 35 15.99
2 43 13.01
2.75 53 10.53
… … …
4 180 ~2

CCNY PicoWorks
23 Final Presentation 12/10/2009
 Configuration Design:
Constraints Imposed

Unit of constraint Results

Spatial •Can't use bottom of frame because of
Flight computer board
•Can't mount outside because of solar
panels
Mass •Total subsystem mass of 40g
Precision •CUNYSat places more weight on final
precision than initial transient time

CCNY PicoWorks
24 Final Presentation 12/10/2009
• Introduction
• Problem Statement and Design Specifications
• Design Concepts
• Product Architecture
• Configuration Design
• Parametric Design
• Final Design
• Analysis & Testing
• Prototype Applications
• Recommendations
• Conclusion
• Acknowledgements
CCNY PicoWorks
25 Final Presentation 12/10/2009
Parametric Design
The Issue of the Z- Axis
Due to spatial constraints mentioned before can't mount straight down inside
or outside
 Parametric Design:
Evaluated Concepts
PCB board
Pros: can fit three axes of material
within the satellite
Cons: unsupported ends more
susceptible to damage during
launch
Log Cabin stacks
Pros: strong, minimal non-
magnetic material, most of mass
budget goes to functional
components
Cons: Not enough volume to
create spans of sufficient strength

CCNY PicoWorks
27 Final Presentation 12/10/2009
 Parametric Design:
Final Concept

CCNY PicoWorks
28 Final Presentation 12/10/2009
• Introduction
• Problem Statement and Design Specifications
• Design Concepts
• Product Architecture
• Configuration Design
• Parametric Design
• Final Design
• Analysis & Testing
• Prototype Applications
• Recommendations
• Conclusion
• Acknowledgements
CCNY PicoWorks
29 Final Presentation 12/10/2009
Construction-phase Modifications

CCNY PicoWorks
30 Final Presentation 12/10/2009
 Final Design
(exploded view)

CCNY PicoWorks
31 Final Presentation 12/10/2009
• Introduction
• Problem Statement and Design Specifications
• Design Concepts
• Product Architecture
• Configuration Design
• Parametric Design
• Final Design
• Analysis & Testing
• Prototype Applications
• Recommendations
• Conclusion
• Acknowledgements
CCNY PicoWorks
32 Final Presentation 12/10/2009
 Analysis and Testing
Helmholtz Coil Rotation Duration

• Purpose
• Procedure
• Video

Machining Effects on Magnetic Material

• Purpose
• Procedure
• Table of Results

CCNY PicoWorks
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 Analysis & Testing:
Helmholtz Coil Rotation Duration

Purpose:
to verify that magnetic hysteresis exerts a
measurable stabilization effect at the mass
calculated

CCNY PicoWorks
34 Final Presentation 12/10/2009
 Analysis & Testing:
Helmholtz Coil Rotation Duration
Procedure
i. Suspend mock CubeSat from string
ii. Set variable parameters for test run
iii. Wind 7turns
iv. Release and start timer
v. Stop timer when CubeSat comes to complete
rest

CCNY PicoWorks
35 Final Presentation 12/10/2009
 Analysis & Testing:
Helmholtz Coil Rotation Duration
Test #1 Test #2 Test #3 Test #4 Test#5 Test #6 Test #7

Suspension
material Shoelace Shoelace Shoelace Shoelace Shoelace Shoelace Shoelace
Turns 7 7 7 7 7 7 7
Elapsed
time 4:37 6:20 5:22 6:28 6:50 7:38 4:34
Magnets
Attached? Yes Yes Yes Yes Yes Yes Yes
Hysteresis
Rod
Attached? No No No No Yes Yes Yes
Coils
Energized? No Yes No Yes No Yes Yes
Mounting Top Top Side Side Side Side Top
Suspension
Length 5" 5" 5" 5" 5" 5" 5"

CCNY PicoWorks
36 Final Presentation 12/10/2009
 Analysis & Testing:
Machining Effects on Magnetic Material

Purpose:
To verify water cooling as a viable method of
negating demagnetizing effects of machining
magnetized material

CCNY PicoWorks
37 Final Presentation 12/10/2009
 Analysis & Testing:
Machining Effects on Magnetic Material
Procedure
i. Notch Alnico-5 bar
ii. Secure in vise and strike with hammer
iii.Measure and record magnetic field strength
iv. Secure in vise
v. Alternate between grinding and dousing with
water
vi. Measure and record magnetic field strength

CCNY PicoWorks
38 Final Presentation 12/10/2009
 Analysis & Testing:
Machining Effects on Magnetic Material

Before Grinding Post Grinding Delta

Flat surface 613 Gauss 590 Gauss -3.75%

Rough (Ground) -770 Gauss -717 Gauss -6.88%

Surface

CCNY PicoWorks
39 Final Presentation 12/10/2009
• Introduction
• Problem Statement and Design Specifications
• Design Concepts
• Product Architecture
• Configuration Design
• Parametric Design
• Final Design
• Analysis & Testing
• Prototype Applications
• Recommendations
• Conclusion
• Acknowledgements
CCNY PicoWorks
40 Final Presentation 12/10/2009
 Prototype Applications
• Future of CUNYSat-1
– Research and methods conducted by
PicoWorks will be used to develop the ADCS
system once CUNYSat-1 obtains a launch
vehicle and orbital profile

CCNY PicoWorks
41 Final Presentation 12/10/2009
• Introduction
• Problem Statement and Design Specifications
• Design Concepts
• Product Architecture
• Configuration Design
• Parametric Design
• Final Design
• Analysis & Testing
• Prototype Applications
• Recommendations
• Conclusion
• Acknowledgements
CCNY PicoWorks
42 Final Presentation 12/10/2009
 Recommendations
• Omni directional antenna should be utilized
• Torquer coils should be utilized for greater
pointing accuracy

CCNY PicoWorks
43 Final Presentation 12/10/2009
• Introduction
• Problem Statement and Design Specifications
• Design Concepts
• Product Architecture
• Configuration Design
• Parametric Design
• Final Design
• Analysis & Testing
• Prototype Applications
• Recommendations
• Conclusion
• Acknowledgements
CCNY PicoWorks
44 Final Presentation 12/10/2009
 Conclusion
• Procedure developed for design of passive
ADCS
• Custom-built magnets should be ordered
• Helmholtz test should be conducted under
more controlled conditions

CCNY PicoWorks
45 Final Presentation 12/10/2009
• Introduction
• Problem Statement and Design Specifications
• Design Concepts
• Product Architecture
• Configuration Design
• Parametric Design
• Final Design
• Analysis & Testing
• Prototype Applications
• Recommendations
• Conclusion
• Acknowledgements
CCNY PicoWorks
46 Final Presentation 12/10/2009
 Acknowledgements
• Dr. Charles Watkins
• Mechanical Engineering Department
• Dr. Shermane Austin
• Mr. Chen
• CalPoly CubeSat program
• SAE-CCNY

CCNY PicoWorks
47 Final Presentation 12/10/2009