Theia ESAT User Manual

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ESAT U

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The information contained in this document is confidential and only for the information of the

intended recipient. It may not be used, published or redistributed without the prior written consent of

Theia Space.

Universidad Politécnica de Madrid - Pozuelo de Alarcón - 28223 Madrid - Spain

Web:

http://www.theiaspace.com

SER

Jacobo Rodríguez

THEIA-UM-ESAT001

10/01/2017

Initial

Limited

Theia Space, E-USOC, Campus de Montegancedo

Telephone: +34 91 452 4925 - Email:

ANUAL

info@theiaspace.com

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Page 1 The information contained in this document is confidential and only for the information of the intended recipient. It may not be used, published or redistributed without the prior written consent of Theia Space. Theia Space, E-USOC, Campus de Montegancedo Universidad Politécnica de Madrid - Pozuelo de Alarcón - 28223 Madrid - Spain Web: http://www.theiaspace.com...
Page 2 THEIA-UM-ESAT001 Issue 1, Rev 2 Page 2/62 S I G N A T U R E S S H E E T Title ESAT User Manual issue revision Prepared by Signature(s) Date Jacobo Rodríguez 10/01/2017 Approved by: Signature(s) date Ana Laverón...
Page 3 Overall revision 09/01/2017 Updated Annex A (assembly guides) 10/01/2017 C H A N G E R E C O R D Issue: 1 Revision: 2 reason for change page(s) paragraph(s) Updated Annex A (assembly guides) File: THEIA-UM-ESAT001-i1-r2.docx Theia Space, UPM...
Page 4: Table Of Contents
User equipment requirements ................... 13 4.2. Server setup ......................... 14 4.3. Workstation setup ....................... 15 4.4. Configuring ESAT unit LAN settings ............... 16 4.5. Safety ..........................19 5. Electrical Power Subsystem (EPS) .................... 20 5.1. Solar panels ......................... 20 5.2.
Page 5 THEIA-UM-ESAT001 Issue 1, Rev 2 Page 5/62 8. ESAT structure and assembly ....................48 8.1. Structure description ....................49 8.2. ESAT assembly ......................50 8.3. ESAT disassembly ...................... 52 9. ESAT remote operation ......................53 Annex A. Assembly guides........................ 62 File: THEIA-UM-ESAT001-i1-r2.docx...
Page 6: Introduction
Issue 1, Rev 2 Page 6/62 1. Introduction ESAT is a demonstrator and education nanosatellite developed as a flexible platform able to support training, development and testing activities on ground, both in the space industry and in the space engineering education environments.
Page 7: Scope
On-Board Computer Attitude Determination & Control Subsystem Section 8 describes the ESAT structure and the steps to perform the full integration of the satellite. Section 9 provides a guide for the remote operation of the integrated ESAT. Procedural instructions for the use of the ESAT unit and its components are provided throughout the document using the following notation: [Step number].
Page 8: References
Ground (electrical) Ground Support Equipment Graphical User Interface Hardware Interface Inertial Measurement Unit MPPT Maximum Power Point Tracking On-Board Computer Operating System Reference Document Real Time Clock Solar Panel Software Telecommand Test point Telemetry Workstation File: THEIA-UM-ESAT001-i1-r2.docx Theia Space, UPM...
Page 9: Esat Components
OBC o ADCS Details on these systems and their operation can be found in sections 5-7. All subsystem boards are connected through the ESAT header, which is based on a PC104 interface (Figure 3). File: THEIA-UM-ESAT001-i1-r2.docx Theia Space, UPM...
Page 10: Ground Support Equipment (Gse)
MTQX ENMTQ MOSI MISO TEST MISO MOSI Figure 3: ESAT header map (left column = inner pins, right column = outer pins). 3.2. Ground Support Equipment (GSE) Rotatory table Magnets 12V power supply Sun simulator protoboard Figure 4: Ground Support Equipment.
Page 11: Tools And Accessories
THEIA-UM-ESAT001 Issue 1, Rev 2 Page 11/62 ESAT units are provided with a set of Ground Support Equipment that allows to make use of the complete functionality of the satellite: Magnetic field simulator, consisting of 2 magnets in opposing stands.
Page 12: Esat Software
ESAT via USB 4. Work environment setup This section details how to set-up the laboratory environment to work with ESAT. As a minimum, a properly configured workstation running a local server is necessary to communicate with the satellite.
Page 13: User Equipment Requirements
USB connection to a workstation; the workstation routes the communication between the ESAT unit and the Server (dashed lines in Figure 5). The ESAT Server runs a web user interface (GUI) to which different workstations can connect to control the ESAT units.
Page 14: Server Setup
Page 14/62 4.2. Server setup To set-up the ESAT Server, either in a dedicated machine (remote server) or in a Windows workstation (local server), perform the following steps: 1. Configure a WiFi LAN in the laboratory. Check with your network administrator and note the LAN SSID and password.
Page 15: Workstation Setup
In this case the Server can be launched running Server_launcher.bat To stop the ESAT Server at the end of a work session click on the Power-off button and close the GUI window. Note: in case of a wrong ESAT Server installation, it is recommended to stop any running Server...
Page 16: Configuring Esat Unit Lan Settings
1. Ensure no power is provided to the EAST unit and its boards: disconnect USB cable, 12V power supply, Arming Plug and Battery Connector, as necessary. 2. If the ESAT unit is assembled, disassemble it until the OBC board and its WiFi module are accessible. Refer to section 8.
Page 17 4.3 installed) using the provided USB cable. [install location]/Energia_16M_ESAT/energia.exe 6. Run the Energia software ( ) and select the serial port of the WiFi programming module (Tools > Serial Port). Figure 9: Energia main window. File: THEIA-UM-ESAT001-i1-r2.docx Theia Space, UPM...
Page 18 10. Re-install the WiFi module on the OBC board. Ensure all pins are correctly aligned and proceed carefully to avoid bending the module’s pins. The ESAT unit is now configured to automatically connect to the WiFi LAN and the Server after power on.
Page 19: Safety
Page 19/62 4.5. Safety ESAT is designed to be safe when handled properly, but its components and operations may cause hazards for the operator and risks of damaging the hardware if not handled with the necessary care. Always follow the instructions provided in this manual, and follow these general rules:...
Page 20: Electrical Power Subsystem (Eps)
Figure 11 shows a block diagram of the power system. Figure 11: ESAT power system; solar panel 3 represents panels 1+2 connected in series. By connecting the solar panels either to the EPS main board or to the BM Solar Panel inputs, two...
Page 21 Page 21/62 Sun sensor connector (to OBC) Sun sensor (back side) SP1/SP2 connector (to EPS or BM): Figure 12: ESAT solar panel (back view). Solar panel interfaces: Solar Panel 1/2 (SP1/SP2) connector:  Solar panel power: SP+, SP-  Temperature sensor interface (I2C): GND, Vcc, SDA, SCL...
Page 22: Eps Main Board Layout And Features
The EPS main board is in charge of ESAT’s electrical power management, including power conversion and distribution to the rest of the ESAT systems. The board contains the EPS controller, which runs the EPS software handling the EPS data and interfaces.
Page 23: Eps Main Board Operation (Stand-Alone)
 Communication with ESAT OBC 5.3. EPS main board operation (stand-alone) The EPS main board can be operated in stand-alone mode, i.e. without connecting it to other ESAT boards. This requires the use of a USB connection to the user workstation (WS) for communication and control of the board.
Page 24 EPS functions at a hardware level (i.e. without software processing); the calibration of EPS telemetry values. EPS main board control (via USB): To control the EPS main board functions using the ESAT GUI, perform the following steps: 1. Power up 1.1. EPS main board >...
Page 25 Tsp2 Temperature solar panel 2 OBC Telemetry Name Description Status register 1 (see below) Status register 2 (see below) The SR1 and SR2 telemetry fields contain the following ESAT status registers: Status 1 (SR1) Spare Spare Spare Spare Spare Spare...
Page 26 ESAT GUI > Commands > EPS commands > Use the Toggle 5V/3.3V commands to power on and power off the 5V/3.3V switchable lines in the ESAT header. This is used to power on/off the devices connected to these lines in other boards attached to the ESAT header.
Page 27: Battery Manager (Bm) Layout And Features
THEIA-UM-ESAT001 Issue 1, Rev 2 Page 27/62 The ESAT status registers indicate which peripherals are detected. This is useful information in two situations: When connecting new devices to the EPS main board, to verify they are properly detected and the EPS controller is able to communicate with them.
Page 28: Bm Operation (Stand-Alone)
Only connect the provided 12V power supply to the BM charging port. The PRES jumper shall be previously connected to prevent overvoltage and damage to ESAT components. Only connect the batteries to the BM board using the provided connectors.
Page 29 Figure 16: DET system. The DET system can be used/verified in stand-alone mode, using the ESAT GSE as described hereafter. Caution: when changing the BM electrical configuration (e.g. connecting/disconnecting jumpers, connecting cables and/or external equipment to the BM), make sure that the batteries are disconnected to avoid possible damage to the batteries and BM.
Page 30 15-25 cm. When the solar panels are illuminated their current will charge the capacitor, which will increase its voltage up to the shunt regulator’s activation voltage (8.2 – 8.4V). This voltage will File: THEIA-UM-ESAT001-i1-r2.docx Theia Space, UPM...
Page 31: Eps Integration
Connect batteries (two connectors). 5.6. EPS integration To integrate and operate the complete ESAT power system (BM + EPS main board + solar panels), perform the following steps. Note: the steps are indicated to use the MPPT power management system. DET can be used by connecting the JP1 jumper and the solar panels to the BM board.
Page 32 Figure 19: ESAT stack bar and interface bolt (left); four spacers (right). 1.8. BM board > Install on ESAT stack bars, slide down until the board rests on the interface bolts. 1.9. Spacers (four) > Install on ESAT stack bars, over BM board.
Page 33 EPS main board, with the PRES jumper already connected. When the PRES jumper is not present the BATT+ voltage in the ESAT header is 0 V. The batteries charge should be high enough (recommended battery voltage > 7.5 V) to allow a stable EPS operation.
Page 34 MPPT mode (e.g. after power up). MPPT operation is described in detail in step 3. 2.5. ESAT GUI > Telemetry > EPS Telemetry > Test different illumination conditions (lamp distance and position with respect to the solar panels) and note their effect in the solar panels and battery voltages and currents for future reference.
Page 35 Verify that the connected devices (BATT, TS1, TS2, DET) are reported in the SR1 and SR2 telemetry fields. 3. MPPT operation ESAT’s boost-type MPPT controllers work as per the following principle: being V the input voltage (i.e. solar panel voltage) and V the output voltage (i.e.
Page 36 MPPT (default): D is set dynamically to the value that provides the maximum power output at every moment. This is the nominal operation mode when working with the ESAT MPPTs. Sweep: performs an ascending-descending sweep of D values (between 0 and 1). This allows obtaining the V-I curves of the solar panels (Figure 21).
Page 37 Connect to WS and to EPS main board’s USB port. 3.1.10. USB cable > 3.1.11. User WS > Start USB communication and open ESAT GUI. 3.1.12. ESAT GUI > Configuration > Select ESAT # and press Connect. 3.2. Lamp (GSE) >...
Page 38 Issue 1, Rev 2 Page 38/62 3.3. ESAT GUI > Telemetry > EPS Telemetry > By default, the EPS will be configured in MPPT mode, automatically adjusting the solar panel voltage to obtain maximum power. Change the distance from the lamp to the solar panel to verify how the EPS adjusts the panel working point (SP input voltage and current change).
Page 39: On-Board Computer (Obc)
6. On-Board Computer (OBC) 6.1. OBC layout and features The OBC is ESAT’s main computer, and is in charge of the overall management of the satellite functions. The OBC board houses a number of peripherals, including the ESAT WiFi module, ADCS sensors, the ESAT Real Time Clock and a microSD card reader.
Page 40: Obc Operation (Stand-Alone)
Page 40/62 ESAT’s Real Time Clock (RTC) The OBC thus allows a user to remotely control and monitor the ESAT systems using telemetry and commands from the user WS (see Figure 5): Telecommands: user WS → Server → WiFi LAN → OBC → ESAT subsystems Telemetry: ESAT subsystems →...
Page 41 Description Alias 0x02 0x69 Inertial Measurement Unit (IMU) 0x68 Real Time Clock (RTC) microSD Card UART ESP8266 Wifi module The ESAT status registers indicate which peripherals are detected. This is useful information in two situations: File: THEIA-UM-ESAT001-i1-r2.docx Theia Space, UPM...
Page 42 4.1. OBC board > 4.2. ESAT GUI > Configuration > Select ESAT# corresponding to WiFi connection and press Connect. This will give access to the same OBC telemetry as in steps 2-3, through the WiFi module. 5. Power off Connect peripherals power jumper in ‘Default’ position.
Page 43: Attitude Determination And Control Subsystem (Adcs)
The ESAT ADCS provides information and control of the satellite’s orientation (azimuth) and angular velocity in the vertical (Z) axis. The ESAT ADCS board hosts the actuators (reaction wheel and magnetorquers) used to change the satellite’s azimuth. In addition, the ADCS attitude sensors and the...
Page 44 Issue 1, Rev 2 Page 44/62 Figure 25: ADCS board. ADCS board interfaces: ESAT header X- and Y-LEDS (magnetorquers status visual interface) Features/functions: Z-axis attitude control through the operation of one reaction wheel:  Controllable wheel rotation speed (-7000 to 7000 rpm) (note: control is performed from OBC).
Page 45: Adcs Operation (Stand-Alone)
 Maximum magnetic torque 7.2. ADCS operation (stand-alone) The complete ADCS functionality can only be used when ESAT is fully integrated, as explained in section 9. However, some of the functions of the ADCS sensors and actuators can be used or verified in stand-alone mode.
Page 46 Use the LDR connector cable labels as reference. Actuators control: The ADCS board has no controllable software, but the ESAT GSE can be used to verify the functioning of the ADCS actuators, by allowing the operator to supply power and control signals directly to the ADCS board.
Page 47 2.2. Multimeter / oscilloscope > Measure the tachometer signal in the GND, TCH terminals of the ESAT header. The speed of the wheel is proportional to the frequency of the observed pulses. 2.3. ADCS board > Disconnect cables from PWM and TCH on ESAT header. Wait until the wheel stops.
Page 48: Esat Structure And Assembly
THEIA-UM-ESAT001 Issue 1, Rev 2 Page 48/62 8. ESAT structure and assembly Figure 26: Assembled ESAT and reference frame. Figure 27: Assembled ESAT, top view. File: THEIA-UM-ESAT001-i1-r2.docx Theia Space, UPM...
Page 49: Structure Description
The top, bottom, side and solar panels are fixed to this frame. Four stack bars are installed along the inner side of the rails to guide and support the ESAT system boards. Spacers are used to keep a controlled distance between the boards.
Page 50: Esat Assembly
Page 50/62 8.2. ESAT assembly All ESAT components have a defined installation position. The full assembly of the ESAT unit must be performed following the procedure described in this section. Caution: do not apply excessive force to any bolt, nut or structure element during assembly to prevent structural damage.
Page 51 Page 51/62 Figure 30: ESAT stack bar and interface bolt 1.8. BM board > Install on ESAT stack bars, slide down until the board rests on the interface bolts. 1.9. Spacers (four) > Install on ESAT stack bars, over BM board.
Page 52: Esat Disassembly
5.2. Upper frame > Install on ESAT stack bars. Keep frame side with A, B, C, D positioning marks on the top side, and keep marks aligned with the rest of the stack. Fix upper frame to rails using four bolts.
Page 53: Esat Remote Operation
EPS. During operation, the EPS will automatically select the power source which provides the highest voltage (batteries or USB port). The EPS lines in the ESAT header will provide power to the following ESAT systems: File: THEIA-UM-ESAT001-i1-r2.docx...
Page 54 5V, switchable: ADCS board 5V, non-switchable: None OBC is programmed to switch on the 3.3V and 5V switchable lines after power up, so all ESAT systems will be powered on automatically (this behaviour can be changed by re-programming the OBC).
Page 55 Magnetic angle Sun_abs Sun angle, inercial Gyro Gyro reading (Z-axis angular speed) Magnetic actuation (MTQ status) Sun_rel Sun angle, relative The SR1 and SR2 telemetry fields contain the following ESAT status registers: Status 1 (SR1) Spare Spare Spare Spare Spare Spare...
Page 56 EPS operational conditions and commands can be used:  Switching on/off 3.3V and 5V lines. Note: switching off the 3.3V line will disable the WiFi module and communication with ESAT will be lost. Communication can be re-established by: File: THEIA-UM-ESAT001-i1-r2.docx Theia Space, UPM...
Page 57 EPS main board > Disconnect arming plug. This will power off the ESAT. 4.2. ESAT unit > Install on GSE turntable: fit ESAT rails into turntable slots and fix using table thumbscrews (four) (Figure 31). Fixation screw Rail slot Balancing weights Figure 31: Rotatory table.
Page 58 It is recommended to draw a reference mark in the balanced position, to allow to quickly install the ESAT in the same position and avoid having to re-balance the table in future uses. 4.5.
Page 59 MTQX/Y polarity is used to set the polarity of the X-/Y-axis magnetorquer to either positive or negative. The result can be observed in the ADCS board LEDs, in the ESAT rotation (each polarity defines a different equilibrium position for the magnetic angle)
Page 60 PID parameters (for both wheel speed control and attitude control) can be changed to adjust the ESAT behaviour under these control laws. B. MTQ control: 1. Stop wheel (it is recommended to send this command even if the wheel is not rotating).
Page 61 Motor duty Set wheel speed (rpm) Enable MTQ 6. Power off 6.1. EPS main board > Disconnect arming plug. This will power off the ESAT. 6.2. BM board > Disconnect PRES jumper. 6.3. Rotatory table > Remove turntable from stand.
Page 62: Annex A. Assembly Guides
THEIA-UM-ESAT001 Issue 1, Rev 2 Page 62/62 Annex A. Assembly guides. File: THEIA-UM-ESAT001-i1-r2.docx Theia Space, UPM...
Page 63: List Of Components
List of components Bottom Panel ESAT 2x Solar Panel -X Side Panel Top Panel -Y Side Panel 12V power supply USB 2.0 cable WIFI Programming Board MicroSD adapter PRES jumper (2-pin), Arming plug jumper (3-pin) 16x 1.5 mm hex bolt, 6 mm-length 8x 1.5 mm hex bolt, 8 mm-length...
Page 64 ESAT Panels Assembly 1.5 mm L-key Solar panels installation ESAT (without panels) 2x Solar Panel 8x 1.5 mm hex bolt, 8 mm-length Before installing the panels, connect: SP1 and +Y cable connectors to Solar Panel 1; SP2 and +X cable connectors to Solar Panel 2.
Page 65 Protection panels installation Top + Bottom Panels ESAT with solar panels 16x 1.5 mm hex bolt, 6 mm-length Side Panels (-X, -Y) Before installing the panels, connect: -X cable connector to -X Panel; -Y cable connector to -Y Panel. Theia Space info@theiaspace.com...
Page 66 Hex L-key set 6x Balancing weight 4x 2 mm hex bolt, 14 mm-lenght Jumper cables 24x 3 mm hex bolt, 14 mm-lenght Electronic components 8x 3 mm hex bolt, 16 mm-lenght Theia Space info@theiaspace.com tel.: +34 91 452 4925 www.theiaspace.com...
Page 67 Fix clamp to base with 3 mm L-key. Perform these steps for the two stands. Magnets installation N, S magnets 2x Assembled magnet stand Install magnets on bar tips and fix with 2 mm L-key. Theia Space info@theiaspace.com tel.: +34 91 452 4925 www.theiaspace.com...
Page 68 Perform these steps for the four bars. Balancing hoop assembly 4x Assembled bars 4x Hoop segment 8x 3 mm hex bolt, 14 mm-length Assemble parts as shown in 2.1 with 3 mm L-key. Theia Space info@theiaspace.com tel.: +34 91 452 4925 www.theiaspace.com...
Page 69: Turntable Assembly
Needle screw has a sharp point, handle with caution. Turntable assembly Balancing hoop Turntable base 8x 3 mm hex bolt, 16 mm-length Fix clamps to turntable base with 3 mm L-key. Theia Space info@theiaspace.com tel.: +34 91 452 4925 www.theiaspace.com...
Page 70 270 mm bar, Ø 8 mm Stand base 8x 3 mm hex bolt, 14 mm-length Fix clamp to bar and base with 3 mm L-key. Keep the screwed bar tip at the top. Theia Space info@theiaspace.com tel.: +34 91 452 4925 www.theiaspace.com...