CarboNIX User Manual
Revision 2.0 /06.09.2022
© 2022 Exolaunch GmbH. All rights reserved. Exolaunch GmbH is the owner of the copyright in this work, and no portion hereof is to be copied, reproduced, or disseminated without the prior written consent of Exolaunch GmbH.
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Table of Contents
1.
Quick Reference ................................................................................................................................................................. 4
2.
Introduction ...................................................................................................................................................................... 5
2.1 What is CarboNIX ............................................................................................................................................................ 6
2.2 Qualification Status ....................................................................................................................................................... 10
2.3 Components and Features ........................................................................................................................................... 11
2.3.1 S-Ring .......................................................................................................................................................................... 12
2.3.2 S-Ring Cable Tie Mounts ............................................................................................................................................ 13
2.3.3 L-Ring .......................................................................................................................................................................... 13
2.3.4 Separation Switch ...................................................................................................................................................... 16
2.3.5 Separation Connector ................................................................................................................................................ 16
2.3.6 Separation Switch and Connector Clocking ............................................................................................................. 17
2.3.7 Harness Routing on the S-Ring ................................................................................................................................. 18
2.3.8 Remove Before Flight (RBF) Elements ..................................................................................................................... 18
3.
System Description ........................................................................................................................................................ 20
3.1 Coordinate System ........................................................................................................................................................ 21
3.2 Mass ................................................................................................................................................................................ 21
3.3 Mounting Configurations .............................................................................................................................................. 22
3.4 Mounting Hole Patterns ................................................................................................................................................ 23
3.5 Keep-Out Dimensions ................................................................................................................................................... 24
3.6 Maximum Loads ............................................................................................................................................................. 25
3.7 Stiffness ......................................................................................................................................................................... 25
3.8 FEM Modeling ................................................................................................................................................................ 26
3.9 Minimum Stiffness Requirements ................................................................................................................................ 26
3.10 Separation Velocity ..................................................................................................................................................... 27
3.11 Rotation Rate ............................................................................................................................................................... 28
3.12 Separation Shock ........................................................................................................................................................ 28
3.13 Electrical Interfaces.................................................................................................................................................... 29
3.13.1 DSub-9 Connectors .................................................................................................................................................. 29
3.13.2 Separation Signal ..................................................................................................................................................... 30
Страница 1: ...ts reserved Exolaunch GmbH is the owner of the copyright in this work and no portion hereof is to be copied reproduced or disseminated without the prior written consent of Exolaunch GmbH 1 44 Microsat...
Страница 2: ...Cable Tie Mounts 13 2 3 3 L Ring 13 2 3 4 Separation Switch 16 2 3 5 Separation Connector 16 2 3 6 Separation Switch and Connector Clocking 17 2 3 7 Harness Routing on the S Ring 18 2 3 8 Remove Befor...
Страница 3: ...tch Installation 32 4 1 2 Separation Connector Installation 33 4 1 3 Installing S Ring and L Ring 33 4 2 Operation 34 4 2 1 Tools and Equipment 34 4 2 2 Status at Delivery 35 4 2 3 Locking the Pusher...
Страница 4: ...t diameter mm 3 5 130 310 395 545 Outer keep out diameter mm 300 475 560 700 Mass kg S Ring ST kg 3 2 0 185 0 337 0 420 0 490 S Ring IM kg 0 218 0 409 0 470 0 593 L Ring threaded inserts kg 1 407 2 42...
Страница 5: ...2022 2022 Exolaunch GmbH All rights reserved Exolaunch GmbH is the owner of the copyright in this work and no portion hereof is to be copied reproduced or disseminated without the prior written conse...
Страница 6: ...d In addition every pusher arm in the spring pusher system is linked together and moves at the same velocity guaranteeing a tip off rate of less than 2 deg s regardless of the location of the satellit...
Страница 7: ...ted during separation making it very gentle on delicate satellite components Relative to other separation systems on the market CarboNIX is virtually shock free Low Tip Off Rates The average tip off r...
Страница 8: ...reof is to be copied reproduced or disseminated without the prior written consent of Exolaunch GmbH 8 44 Figure 4 Three CarboNIX 15 units were used on the June 13 2020 SpaceX Starlink 9 Rideshare Miss...
Страница 9: ...in this work and no portion hereof is to be copied reproduced or disseminated without the prior written consent of Exolaunch GmbH 9 44 CarboNIX 8 CarboNIX 15 x4 Figure 7 CarboNIX 8 ready for microsat...
Страница 10: ...ar the most common launch configuration is on the Falcon 9 Transporter missions which the CarboNIX mounted in the wall mounted configuration Contact Exolaunch for details The CarboNIX lock mechanism i...
Страница 11: ...copyright in this work and no portion hereof is to be copied reproduced or disseminated without the prior written consent of Exolaunch GmbH 11 44 2 3 Components and Features The main components of th...
Страница 12: ...the lowest flyaway mass of any microsatellite separation system The S Ring ST is able to achieve such an incredibly low weight due to its unique protrusions at each of the screw mounting points These...
Страница 13: ...r In can be fastened to the launch vehicle with either 28 or M6 screws 2 3 3 1 Lock Mechanism The locking mechanism uses a unique magnetic system that can be released either using an electrical input...
Страница 14: ...these rings grip the feet of the S Ring and prevent any movement Once the lock mechanism releases the springs rotate the rings apart unclamping and releasing the S Ring 2 3 3 3 Pusher Mechanism Once...
Страница 15: ...nt sensors which transmit the deployment status back to the launch vehicle Deployment sensors are located in two positions These sensors indicate whether the locking mechanism has been opened and whet...
Страница 16: ...eparation has occurred Separation switches are for satellite side telemetry only Launch vehicle side telemetry shall be transmitted through the built in deployment sensors 2 3 5 Separation Connector T...
Страница 17: ...lite before separation All electrical interfaces must adhere to limitations determined by the launch authority 2 3 6 Separation Switch and Connector Clocking The separation switch and separation conne...
Страница 18: ...Satellite manufacturers are encouraged to select the connector of their choice when manufacturing the pigtail 2 3 8 Remove Before Flight RBF Elements CarboNIX uses two types of RBF elements Two pins a...
Страница 19: ...engaged This can simplify the integration process as the RBF will automatically lock the system shut once the clamp rings are closed The red indicator on the RBF provides a visual indication of the s...
Страница 20: ...22 2022 Exolaunch GmbH All rights reserved Exolaunch GmbH is the owner of the copyright in this work and no portion hereof is to be copied reproduced or disseminated without the prior written consent...
Страница 21: ...mm in the Z direction The Y axis is defined by the first mounting point counterclockwise from the lock mechanism when viewed from the top satellite side with Y pointing in the direction of the lock me...
Страница 22: ...be mated with the launch vehicle and the satellite in the following ways In all cases M6 fasteners can be replaced with fasteners as desired M6x25 or 28 x 1 NL6ss Nord Lock Washer M6x25 or 28 x 1 NL6s...
Страница 23: ...he S Ring ST Launch vehicle side counterbores are not required but may be desired to increase shear load capability Table 3 CarboNIX Interface Dimensions Description Letter C8 C15 C18 C24 Number of mo...
Страница 24: ...tion protrusions shall not block access to the DSub 9 connectors and harness routing Fit check CAD can be provided on request Table 4 CarboNIX Keep out Volume Description Letter C8 C15 C18 C24 Inner k...
Страница 25: ...as well as the load profile of the launch vehicle and the mounting orientation to ensure that no single segment is overloaded 3 7 Stiffness More than strength stiffness is typically the driver when de...
Страница 26: ...her mounted on the SpaceX Dispenser Ring CarboNIX height 50mm is to be represented via an additional RBE2 element connecting CarboNIX CBUSH with the launcher interface node 3 9 Minimum Stiffness Requi...
Страница 27: ...gths has no effect on the tip off rate Figure 37 demonstrates the relationship between satellite mass and deployment speed relative to different values of the total spring energy Figure 37 Deployment...
Страница 28: ...arate with near zero initial rotation regardless of the satellite mass distribution Results from satellites deployed in space show an average rotation rate of 0 6 deg s across all three axes No axis r...
Страница 29: ...s considered the shock loads generated by CarboNIX which reach the payload are lower than clamp band systems by up to a factor of 10 across the majority of the frequency spectrum 3 13 Electrical Inter...
Страница 30: ...nt mA 500 Voltage Range V 24 36 Nominal Pulse Duration ms 500 Maximum No fire Current mA 120 Duty Cycle cycle time 30s 10 3 13 3 Grounding CarboNIX provides an electrically conductive path from the sa...
Страница 31: ...022 Exolaunch GmbH All rights reserved Exolaunch GmbH is the owner of the copyright in this work and no portion hereof is to be copied reproduced or disseminated without the prior written consent of E...
Страница 32: ...ration Switch Installation If the customer chooses to use the separation switch it will be delivered earlier than the full CarboNIX unit to provide sufficient time to integrate it with the satellite h...
Страница 33: ...re clocking is correct See Section 7 2 2 Insert all 24 screws DIN 912 M6x25 BUMAX 109 or NAS1351N4 16 with NL6ss Nord Lock washers 3 Tighten all screws in a clockwise or counterclockwise pattern CAUTI...
Страница 34: ...by case basis 4 2 1 Tools and Equipment The CarboNIX is delivered with the following items as standard Tool Description QTY Picture Angled Circlip Pliers Knipex 44 21 J31 Primary pliers for engaging...
Страница 35: ...ritten consent of Exolaunch GmbH 35 44 4 2 2 Status at Delivery CarboNIX shall be stored and delivered in a low energy state with all springs in their relaxed position Specifically this means that The...
Страница 36: ...d with the L Ring with the arms in the extended configuration This step shall be performed by two people CAUTION An uncontrolled release of the pusher arms will cause SEVERE AND IRREPARABLE DAMAGE to...
Страница 37: ...ed The clamp ring RBF pins are installed and the red indicator is visible The lock mechanism is disengaged Optional The pusher arms are secured with RBF pins All required separation switches and separ...
Страница 38: ...ns inserted see 4 2 4 1 To engage the release mechanism all three indicators must be pushed fully within the housing The locks are engaged by pushing first the inhibit pin then the lock indicators 2 I...
Страница 39: ...triggering a release CAUTION The CarboNIX system must be secured with at least one clamp ring RBF pin before this test is performed Failure to do so may cause SEVERE AND IRREPARABLE DAMAGE to both th...
Страница 40: ...2022 Exolaunch GmbH All rights reserved Exolaunch GmbH is the owner of the copyright in this work and no portion hereof is to be copied reproduced or disseminated without the prior written consent of...
Страница 41: ...r of Gravity mm X 9 10 9 16 Y 32 93 33 14 Z 20 78 20 89 Moment of Inertia kgmm X 12637 96 12577 10 Y 7927 67 7876 18 Z 20103 65 19996 87 Product of Inertia kgmm2 YZ 52 68 57 94 XZ 25 62 27 07 XY 1763...
Страница 42: ...ravity mm X 4 97 5 01 Y 32 25 32 62 Z 21 34 21 49 Moment of Inertia kgmm X 57294 84 56896 89 Y 43033 87 42656 94 Z 99134 15 98372 34 Product of Inertia kgmm2 YZ 117 80 129 54 XZ 18 07 19 87 XY 2018 13...
Страница 43: ...tia kgmm X 88449 56 Y 68589 83 Z 156633 83 Product of Inertia kgmm2 YZ 46 19 XZ 6 53 XY 2292 53 L Ring Deployed Center of Gravity mm X 4 22 Y 34 59 Z 21 23 Moment of Inertia kgmm X 89160 95 Y 69216 02...
Страница 44: ...mm X 3 22 3 25 Y 33 98 34 26 Z 22 00 22 14 Moment of Inertia kgmm X 183096 65 181761 36 Y 153910 84 152607 56 Z 335654 89 333032 57 Product of Inertia kgmm2 YZ 83 34 99 42 XZ 6 66 8 17 XY 1821 32 181...
Страница 45: ...no portion hereof is to be copied reproduced or disseminated without the prior written consent of Exolaunch GmbH 45 44 2022 Exolaunch GmbH All rights reserved Exolaunch GmbH is the owner of the copyri...
