Design and AIV for New Space New Rules (components for nano/micro satellite)

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1 Design and AIV for New Space New Rules (components for nano/micro satellite) Stephan Roemer Head of Space Project Development and Space Sales Astro- und Feinwerktechnik Adlershof GmbH 1 Berlin, Germany November 2016

2 Page 2 Astro- und Feinwerktechnik Adlershof GmbH Situated in Technology Park Berlin-Adlershof 1909 First airfield in Germany 1912 Ancestor of German Aerospace Research Center (DVL / DLR) was established 1952 Part of the Academy of Science of the GDR (East Germany) - Institute of Cosmic Science and Technology - Partner of Intercosmos Program Since 1991 second largest technology park in Europe > people in more than companies and research laboratories University Campus

3 Page 3 Astro- und Feinwerktechnik Adlershof GmbH Established October 1993 spin off from the Institute for Space Sensor Technology of the German Aerospace Center (DLR), Berlin-Adlershof Berlin, ~70 employees Markets aviation 12% instruments / optic 18% other 5% aerospace 65% Supplier of components Systems for space / Small System Integrator

4 Page 4 Astro- und Feinwerktechnik Adlershof GmbH Engineering Manufacturing Assembly Integration Test Verification & Qualification PA Dept. Quality Assurance

5 Page 5 Quality Management Processes and Documentation is conform to ECSS-Standards and Certified by ESA Certified according to DIN EN 9100:2010

6 Page 6 Markets and Partners worldwide and beyond Participation on different space missions

7 Page 7 System Competence - Astrofein Systems Subsystems Components Sub-Contractor Strategy: Sub-Contracting (e.g. build to print) as base Components as growing share within the commercialization Subsystems as contribution to large projects within DLR/ESA framework System competency as small system integrator

8 Page8 Complete Satellite Platforms or Components Image cortesy: BIROS, DLR-IOS

9 Deployers for cubesats (until 12U) Flight proven systems based on a patented sequenced deployment and magnetically opening mechanism PSL Family for 1U, 2U and 3U deployer PSL-P System for 3U, 6U and 12 U satellites Qualified for all typical piggy-back launcher

10 Page10 What is New Space Every one has a different understanding what NEW SPACE means. For Astrofein NEW SPACE companies are application driven companies that makes their money with the data products or transmitted/collected data, not with the space hardware These new players comes typically from non-space market and see space only as a tool to bring the required benefits to Earth Mostly mid or big size constellations Business Case and Return-on-Invest is the only important topic(driven by Venture Capital) They are open for new ideas But reliability is still very important Autonomous systems, because of big constellation management/operations

11 Current Markets Currently we see the dividing of the market into different user groups Classical education or technology verification projects (primary for universities) E.g. cubesats, BEESAT, QB-50, Scientific, classical space industry and governmental users E.g. Agencies, Airbus,. TET, Myriade, New Commercial Users NEW SPACE E.g. Planet Labs, One Web This results in different requirements for items for different types of projects

12 Education/Tech Demo Governmental New Space Minimum price High Price Price effective Tendency to make everything by its own (student labour is free of cost) Option to fail, Mission goal is fullfilled at 90% at launch date Complete integrated systems High reliability Only system integrator. Willing to buy as much items as possible. Must be medium reliable, mission must be accomplished Docu: Only ICD or spec Full ECSS documentation ICD, Test reports, Analyses, Specs Weeks/Months of lifetime in orbit 3 to 7 years in orbit 1 to 15 years in orbit Typically 1 to 3 U satellites Nano and micro satellites Nano and micro satellites Delivery times <3 month Delivery times 1 year Delivery times ~ 6 month No PA requirements ECSS Tailored PA requirements Best fit + low price Fit to Requirements and ECSS Performance, price, reliability Low numbers Low numbers High Numbers (>100)

13 Page13 What is the dilemma of NEW SPACE component/subsystem deliverers No one has the heritage in building hundreds of units in short times ECSS or NASA Standard designs no not fit to real mass production Delivery times and costs of classical parts and components (e.g. EEE-parts) are too high Cost of components for mega constellations should be ¼ of classical space components But requirements for reliability are still high (e.g for 10 or 15 years) So there are two main topics: - Design of units for NEW SPACE (Mega) Constellations - Integration, Verification and Testing (AIV) of units for mass production

14 Strategical thoughts for the design of components As much as possible use of former designs and share design between different items Common Part Procurement Mechanical design for Good mass productivity (e.g. milling times) Optimized for price not for mass/performance ratio Completely new EEE-Part approaches Strictly digital interfaces, for plug-and-play Can 2, RS-485 or SPI are most used standards

15 Two options of EEE-Parts selection for components for constellations 1. Using of Automotive EEE-Parts Very good reliability and performance Very good traceability Easy interfaces, common international standard Vibration, temperature and shock testing still done, only Vacuum and radiation testing have to be added High numbers in short time available Obsolescence mostly no issues due to generica 2. Qualification of COTS EEE-Parts Qualification by own program Common parts procurement or design allows to establish high numbered stocks (to avoid obsolescence)

16 Example EEE-Part Up-Screening on component level: Incoming / Visual Inspection Sample size 100% X-Ray (IC's and coils) 100% Outgassing Test (for connectors) on 1 piece per type Thermal Cycling (parameters derived from data sheets) 100% Burn-in (parameters derived from data sheets) 100% These tests are based on MIL-STD-883 Method 5004 (Class Level B screening) and adopted where applicable. Incoming / Visual Inspection: 100% visual inspection is done for every part X-Ray: is done for every integrated circuit and for coils Thermal Cycling: is performed on board-level Burn-in: Burn-in is performed on board-level Outgassing Test: is performed on one piece per connector type for material reference

17 Example EEE-Part Up-Screening on board level: Evaluation boards Electrical testing 21 boards Vibration Electrical testing Half sine shock Electrical testing 5 boards Life Test (accelerated) 5 boards Radiation test (TID) Electrical testing Thermal vacuum Electrical testing Summary of test results

18 Example Gyro AGS-1 (current product): 3 versions: Screened COTS, MIL or similar (both ITAR free) and High Rel/ITAR Tailored ECSS, tailoring of EEE part requirements and up-screening of EEE part, (coordinated with DLR in the TET-project) Common parts and building blocks with other components like RW s, GPS and Magnetic field sensor Reuse of military heritage Digital interface But this is only the first step!

19 Strategical thoughts for integration and testing Mass production lines with automatic and robotic integration Design with a minimum of integration steps and no-or-automatic calibration Pre-assmbled units by sub-supllier Strictly digital interfaces, for plug-and-play Can 2, RS-485 or SPI are most used standards Try to bring the community to common testing standards ISO standardization group lead by Prof. Mengu Cho, Japan New testing philosophies Build partnerships for combining your equipment with the items of other companies (for easier integration), for faster delivery of components/subsystems

20 Testing Philosophy Full ECSS testing, especially environmental testing, is not possible Lots of verification by analysis during design process, including joint SIL and HIL testing with sytsem integrator Requires the existing of mathematical models of all components (e.g. Matlab/Simulink) Qualification process of QM according ECSS Automatic mass unit performance testing of every FM unit 10% of units (or less) for environmental testing of FM s IMPORTANT: Trend analysis of all important parameters, including all design/performance margins Only this allows an early detection of things that start to go wrong do to effects in mass production

21 We see different but important changes in the nano and micro-satellite NEW SPACE community To survive under this new conditions a new thinking, new design and approach is necessary It needs a good understanding on both sides of the supply line The new rising Asian micro-satellite market and the new commercial players in the nano/micro-satellite market has the effect of a re-thinking of the old industry and the agencies The requirements given by NEW SPACE are challenging, but By this development we are prepared for a giant leap in the application driven commercial market (low price, still reliable, short delivery times)

22 Summary Components for constellations Currently the NEW SPACE constellations requires hundreds of units in short time, which can only be reached by: New redundancy approaches on components as well as spacecrafts Redesign for easy and fast manufacturing, integration and testing E.g. Low milling times (easy geometries) Fast assembly (less or no calibration) Easy assembly (not by engineers) Reduced and automatic testing Resulting in less advanced but much cheaper components But still high reliability More like car mass production instead of mechanical art We actually do this in the next generation of ACS components which are just under development

23 To say it in easy words Building NEW SPACE components/subsystem/systems:.. is like buying a mass produced motor cycle instead of a custom bike. There will be still the market for custom bikes which fits perfect to the customer. Unfortunately not every customer is willing to pay and wait a long time for it. For them we need the mass produced ones. NEW SPACE Old and governmental Space

24 Contact Astro- und Feinwerktechnik Adlershof GmbH Stephan Roemer Head of Space Project Development and Space Sales Albert-Einstein- Str Berlin Germany Phone Fax