EXOLAUNCH TestPod User manual

TestPod User Manual
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TestPod
User Manual
Revision 2.0 |October 2022

TestPod User Manual
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Table of Contents
1. Introduction ...................................................................................................................................................................... 3
1.1 Purpose ............................................................................................................................................................................ 4
1.2 Quality Assurance............................................................................................................................................................ 4
1.3 Applicability...................................................................................................................................................................... 4
2.
Exolaunch TestPod........................................................................................................................................................... 5
2.1 Introduction ..................................................................................................................................................................... 6
2.2 Components and Features ............................................................................................................................................. 6
3.
TestPod Porperties and Interfaces ................................................................................................................................ 8
3.1 Physical Dimensions and Mass Properties ................................................................................................................... 9
3.1.1 Mounting Interfaces ..................................................................................................................................................10
3.1.2 Lifting Points ..............................................................................................................................................................11
3.1.3 Structural Characterisitcs and Lifetime................................................................................................................... 12
3.1.4 Flight Representativeness ........................................................................................................................................14
3.2 Cubesat Interfaces........................................................................................................................................................ 15
3.2.1 Introduction................................................................................................................................................................15
3.2.2 Maximum Cubesat Volume ........................................................................................................................................15
3.2.3 Access Windows ........................................................................................................................................................ 17
3.2.4 Rails and Clamps ........................................................................................................................................................ 17
3.2.5 Deployment Wagon.................................................................................................................................................... 18
3.2.6 Door with Set Screws................................................................................................................................................19

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Introduction

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1.1 Purpose
This User Guide describes features of the Exolaunch TestPod and defines the interface requirements for the
Cubesat for developers, who are utilizing the TestPod for mechanical testing, fit-check purposes or shipping. The
TestPod is designed and based on Exolaunch’s EXOpod Cubesat Deployer and complies with the Cubesat Design
Specification Rev. 14.
1.2 Quality Assurance
Quality assurance for the Exolaunch TestPod is ensured at every step of production. The entire production
process fulfils the highest quality assurance requirements. The facilities which manufacture Exolaunch products
such as the TestPod are certified with ISO 9001:2015 standard, which requires regular inspection of the
manufacturing and assembly facilities and ensures a stable quality of the final product.
1.3 Applicability
This document is applicable until it is cancelled or replaced by another issue. This User Guide is a living document
open for all corrections and amendments which occur in the lifetime of the TestPod.

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Exolaunch TestPod

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2.1 Introduction
The Exolaunch TestPod has been developed to facilitate mechanical testing of Cubesats. It allows performing the
full mechanical qualification of a Cubesat inside the TestPod. The TestPod can be easily mounted on a shaker
table or other testing devices and creates a realistic environment, with all mechanical interfaces being the same
as in the EXOpod deployer that is used during an actual launch. This has an additional benefit of enabling the
TestPod to perform Cubesat fit-checks and also allowing a Cubesat to be shipped safely in a Testpod if required.
The system offers both a combination of the highest reliability and user-friendliness.
This document describes the family of TestPods suitable for Cubesats from 1U to 16U, Exolaunch has detailed
documentation on each of the different TestPod sizes that it offers, which is avaliable upon request.
2.2 Components and Features
The main components of the 3U, 8U and 16U TestPods are shown in Figure 2. It features
›A clamping mechanism
›Set screws
›Access windows
›A rigid chassis
›Several mounting interfaces
Sizing Features
Using adapters, it is possible to fit smaller Cubesats inside a larger TestPod. Typically, this involves a Cubesat
going to the next sized up TestPod, for example a 1U CubeSat or 2U Cubesat using a 2U or 1U adapter inside a 3U
TestPod. These adapters are standard U sizes, but can be customized if the Cubesat is uniquely sized. The
adapters are inserted into the TestPod before the Cubesat is intergrated.
Figure 1:
3U TestPod with 1U and 2U adapters

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Clamping Mechanism
The clamping mechanism pushes several clamping feet along the TestPod’s rails inwards when the door is
closed. This compensates for any tolerance gaps that may exist between the TestPod and the Cubesat in the
lateral directions. The Cubesat is held in place safely and unwanted movement is prevented. The same clamping
mechanism is also utilised in Exolaunch’s EXOpod Deployer.
Set Screws
The set screws on the door of the TestPod compensate for dimensional tolerances in the deployment axis and
help fix the satellite in place after the door is closed. This follows a similar purpose to the clamping mechanism
and helps prevent unwanted movement. The door itself is closed and secured by two screws (this position is
taken by RBF pins on the deployer).
Access Windows
There can be up to 16 access windows in total, depending on the size of the TestPod. These access windows are
present on both sides of the TestPod and allow access to the Cubesat during testing, permitting accelerometer
placement and visual inspection.
Chassis
The Testpod’s stiff construction guarantees structural integrity and longevity. The flange is part of the structure
and allows easy mounting of the TestPod on the shaker table with several individual mounting hole patterns.
Figure 2:
Components and
features of the 3U
TestPod. Components
are the same no
matter TestPod size
Deployment
wagon
Set Screw
with fixation
ring
Threaded
holes for lifting
brackets
Rail
Clamping
mechanism
Flange with
mounting holes
Door
Door
latching
mechanism
Access
window
Door lock
Screws

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TestPod Porperties
and Interfaces

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3.1 Physical Dimensions and Mass Properties
The outer dimensions of the three different sizes of TestPod are showing in Figures 3 to 5.
Figure 4: Outer envelope of the 8U TestPod
Figure 3: Outer envelope of the 3U TestPod

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3.1.1 Mounting Interfaces
The 3U TestPod features two mounting hole patterns as shown in Figure 6, with the mounting hole patterns of
the 8U and 16U shown in Figure 7. All the mounting holes are Ø11 mm through-holes for M10 screws with a
nominal tightening torque of 40.0 Nm. The mounting holes have an Ø 18 mm, 5 mm deep counterbore for the
screwhead.
Note: A purchased TestPod can optionally be manufactured with a different hole pattern if required.
Figure 5: Outer envelope of the 16U TestPod
Figure 6:
Mounting interfaces
of the 3U TestPod

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3.1.2 Lifting Points
Every TestPod has four threaded holes on the top side which can be used to attach lifting brackets. The location
of the holes are shown in Figure 2, with an example mounting shown below in Figure 8. The screws are tightened
to 1.0 Nm.
The brackets are strong enough to carry the weight of a fully loaded TestPod with significant margin for lifting any
additional masses, such as the adapter plates.
Figure 7: Mounting interfaces of the 8U and 16U TestPod
Figure 8:
Installed lifting brackets
on the 3U TestPod

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3.1.3 Structural Characterisitcs and Lifetime
The primary structure of the TestPod was designed for rigidity and durability allowing for a high number of test
cycles. The natural frequencies of the different TestPod models are shown below Figure 9. These frequencies
have been determined from a 0.2 g sine sweep test with no mass inside the TestPod.
The number of test cycles that can be run in a TestPod is only limited only by the rails. A general limit is difficult to
define, since the wear on the rails depends mainly on the condition of the Cubesat rails tested inside the TestPod.
Experience shows that a set of rails can be used for 10 - 15 full campaigns or more, provided that the Cubesat is
fully compliant with the CDS and integration and deintegration are performed with care. Figure 12 shows
examples of worn out rails (photo shows an EXOpod deployer).
Figure 9:
Resonances
frequencies
of the 3U
Testpod

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Figure 10:
Resonances
frequencies
of the 8U
Testpod
Figure 11:
Resonances
frequencies
of the 16U
Testpod

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Figure 4 and Figure 5 show the location of the all electrical interfaces of the EXObox.
3.1.4 Flight Representativeness
The CDS does not specify requirements for flight representativeness of a TestPod or test support device of any
kind. The stiffness of the TestPod structure, which is significantly higher when compared to a typical deployment
system on the market, does have an influence on load transmissibility and levels experienced by the Cubesat.
However, this difference is typically accepted by various launch providers and altering the test levels is not
required. The internal mechanical interface in the TestPod is identical to those of an Exolaunch EXOpod deployer.
Figure 12:
Example of strong
wear marks on rails
(Photos show
Exolaunch EXOpod
deploymer)

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3.2 Cubesat Interfaces
3.2.1 Introduction
The Exolaunch TestPod has been developed to follow the Cubesat Design Specification (CDS). However, changes
have been implemented which allow for integrating Cubesats that exceed some dimensions which are specified in
the CDS, while still accommodating fully CDS-compliant Cubesats.
Cubesats are constrained by three separate elements on the deployers: the rails, the deployment wagon, and the
set screws located on the doors. The deployment wagon is the same as in the EXOpod Deployer, only without
the deployment spring.
3.2.2 Maximum Cubesat Volume
General requirements of Cubesats are provided in the Cubesat Design Specification Rev. 13. However, Cubesats in
Exolaunch’s TestPods and Deployers are allowed to exceed some of the constraints imposed by the CDS.
The maximum allowable volume for various Cubesat sizes are outlined in Figure 13 and Table 1. Surface
parallelism and roughness are given in Figure 14. The red areas (rails) mark the Cubesat interfaces with the
TestPod; these dimensions must be followed in order for the Cubesat to fit inside the TestPod. The grey volume
can be used by the Customer in any desired way. The yellow area represents the so-called Tuna Can, and may also
be used by the Customer.
The CDS states that Aluminum 7075, 6061, 5005 and/or 5052 shall be used for both the main Cubesat structure
and the rails. The rails must additionally be hard anodized, no other processes or materials shall be used. Any
deviation from the CDS, such as but not limited to, the use of different materials or surface finishes, i.e. other
forms of anodizing or a chromate conversion dual finish, may inflict damage to the rails.
If the TestPod has been rented from Exolaunch, any such deviation shall be communicated with and approved in
writing.
Figure 13: Maximum allowable outer dimensions for Cubesats launched in an EXOpod. Contact areas with the deployer are marked
red. Picutred in the figure is an example is of a 3U Cubesat.

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Table 1: Maximum Cubesat Dimensions for different TestPod sizes
Description Letter
3U TestPod 8U TestPod 16U TestPod
1U/2U/3U 6U 6U XL 8U 12U 16U
CubeSat Rail Length (Z) [mm] A
1U: 113.5
340.5 365.9 454 340.5 454.02U: 277.0
3U: 340.5
CubeSat Rail Width (X) [mm] B 100.0 226.3 226.3 226.3 226.3 226.3
CubeSat Rail Height (Y) [mm] C 100.0 100.0 100.0 100.0 226.3 226.3
Maximum Space Between Rails (X) [mm] D 87.2 213.5 213.5 213.5 213.5 213.5
Maximum Space Between Rails (Y) [mm] E 87.2 87.2 87.2 87.2 213.5 213.5
Tuna Can Diameter (except 5th tuna can) F 82.0 82.0 87.0+** 87.0 82.0 87.0
12U Tuna Can Depth (except 5. tuna can) G 60.0 60.0 - - - -
16U Tuna Can Depth (except 5. tuna can) G - - - 77.0 77.0 77.0
Number of Tuna Cans - 1 2 2 2 5* 5*
Distance Between Tuna Cans [mm] - - 126.3 126.3 126.3 126.3 126.3
Maximum Mass [kg], RPM -
6.0 12 12 15 22
24
Maximum Mass [kg], BPM 29
Rail Parallelism [mm] - 0.05
Surface Roughness [µm] - 1.6
*The fifth tuna can is located at the center of the deployment
wagon with a diameter of 62 mm and a height of 67 mm.
**The adapter used to accommodate a 6U XL can be modified
to fit custom dimensions.
Figure 14: Cubesat Rail Surface roughness and parallelism

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3.2.3 Access Windows
The Access Windows are located on both sides of the TestPod and total 6, 8 or 16 depending on the model of the
TestPod. These access windows allow for quick and easy access to the Cubesat after its integration for attaching
accelerometers, visual inspection, or for a quick functional test using external ports at any point during a test
campaign. The exact dimensions and location of these Windows for the 16U TestPod are shown in Figure 15.
Measurements start in the deployment wagon plane and from the guidance rails, which are the contact planes of a
Cubesat.
3.2.4 Rails and Clamps
The rails are made of hard-anodized aluminum. As a mechanical interface they are identical to the rails used in
Exolaunch’s EXOpod Cubesat deployers. This provides a flight-like environment for the satellite. To fix the
satellite in the X and Y directions (perpendicular to the direction of deployment) Exolaunch utilizes an array of
adjustable clamps on one of the upper rails that serve to restrain and hold the Cubesat stable when the TestPod’s
doors are closed, see Figure 16. These clamps compensate for any loose tolerances and prevent the satellite from
shaking and rattling around during transportation and testing.
Figure 15:
Dimensions of the
TestPod access
windows using a
16U TestPod as
an example.
Dimensions are
the same across
different TestPod
sizes. Green
Square represents
windows which
would be present
on a 3U TestPod,
Green and Blue for
an 8U TestPod.

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3.2.5 Deployment Wagon
The deployment wagon is situated between the back wall of the TestPod and the Cubesat. In the EXOpod
Deployer it serves to keep the spring in the correct orientation ensuring that the spring force is delivered correctly
to the Cubesat. In the TestPod, the deployment wagon does not carry a spring. It serves only as a mechanical
interface and is fixed in place using four knurled screws located on the back side of the TestPod. When these
screws are removed, a set of pusher tools can be used to facilitate Cubesat de-integration, Figure 17.
Figure 16:
Clamping Mechanism
Figure 17:
Left: Deployment Wagon for the 3U TestPod with knurled screws for fixation.
Right: Pusher tools to facilitate de-integration of the Cubesat.

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3.2.6 Door with Set Screws
The Cubesat is fixed in the direction of deployment by the deployment wagon at the back of the TestPod with four
set screws located on the TestPod door. These are circled on the 3U TestPod as an example shown below in
Figure 18. The set screws are carefully tightened one by one to adapt to the individual size of each satellite.
Unlike the clamping mechanism, the set screws do not apply any force onto the satellite but are only used to
bridge any loose tolerance gaps.
Figure 18:
Door with set screws used to fix
the satellite in the Z-direction
Set Screw
Fixation Ring
Alignment Tooth

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