Assembly, Integration, and Testing of the Delfi-C3 Nanosatellite

Paper number

IAC-08.D1.5.6

Author

Mr. Gerard Brouwer, Delft University of Technology, The Netherlands

Coauthor

Mr. Wouter Jan Ubbels, ISIS - Innovative Solutions In Space BV, The Netherlands

Coauthor

Mr. Bram Vaartjes, Delft University of Technology, The Netherlands

Coauthor

Mr. Frank te Hennepe, OHB-System AG, Germany

Year

2008

Abstract

At the Faculty of Aerospace Engineering of Delft University of Technology, the Delfi-C3 satellite project has been finalised for launch in the second quarter 2008 on a Polar Satellite Launch Vehicle from India. Delfi-C3 is a three unit CubeSat, which uses a Pumpkin CubeSat kit as basis for the structure. However most parts of the kit were modified or replaced by custom-made parts to suit the needs of the project.

This paper provides an overview about manufacturing, assembly, integration and verification activities on subsystems and the proto-flight model until delivery for launch. Furthermore, attention is paid to the experiences and lessons learned in this student project. The presented test plan and activities may serve as a valuable scheme for the next university satellite and the CubeSat community as a whole.

Delfi-C3 is the first nano-satellite of the Delft University of Technology and the fourth Dutch satellite. The satellite was designed and built by the faculties of Aerospace Engineering and Electrical Engineering, Mathematics and Computer Science. The payloads were provided by Dutch industry partners, i.e. two Autonomous Wireless Sun Sensors and four pairs of Thin Film Solar Cells. Furthermore, a radio transponder function is implemented in the transceiver for use by radio amateurs. The satellite has no batteries and has been designed to be single point of failure free.

In the course of the manufacturing, assembly, integration and test program, firstly development tests were done (solar array and antenna deployment mechanisms, antenna pattern test), followed by tests on the subsystems for their functional performance (deployment electronics, solar cell measurement system, payload interface electronics, Electrical Power System, communications system and attitude control system behaviour). Prior to final integration all Printed Circuit Boards were temperature cycled, vacuum baked and tested for their performance on board level. With the completely integrated satellite a proto-flight test program was performed, consisting of vibration test, thermal vacuum test, deployment test, communication tests and performance tests. With regular health checks, the status of the satellite was verified for changes in its behaviour during the proto-flight test program as a whole. In conjunction with testing, the on-board software and the ground system were developed and verified.


Keywords:  Delfi-C3, university satellite, testing, sun-sensor, thin film solar cells, assembly, integration, test, verification, Delft University of Technology

Abstract document

IAC-08.D1.5.6.pdf

Manuscript document

IAC-08.D1.5.6.pdf (🔒 authorized access only).

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