Pujan Dubey, Technical University of Berlin
Paul Thurley, Technical University of Berlin
Anis Haffoudhi, Technical University of Berlin
Pujan Dubey, MSE Student/Structural Lead – Pulse Sat project, Technical University of Berlin
The PULSE Satellite is a cutting-edge 3P picosatellite designed to meet PocketQube standards, combining innovative engineering, precise material selection, and efficient design methodologies to achieve a lightweight yet robust structure. Crafted from anodized aluminium 6061, the primary structure boasts a high strength-to-weight ratio and excellent corrosion resistance, ensuring durability while adhering to stringent weight constraints. Utilizing a framed tubular configuration with precision-cut components, the design achieves efficient mass distribution and enhanced stability. Through extensive iterative processes, the structural components weigh a mere 140 grams, optimizing the total mass allocation of 750 grams for other critical subsystems.
A defining feature of the PULSE Satellite is its innovative antenna deployment mechanism. This system employs a nichrome-wire-based burn circuit to sever nylon restraints, enabling the secure and controlled release of antennas in orbit. Constructed from stainless steel tape, the half-dipole antennas offer flexibility and durability while minimizing mechanical complexity. A passive deployment approach eliminates the need for motors or actuators, reducing weight and potential points of failure. To ensure reliable operation, a microswitch system is integrated, providing confirmation of successful antenna extension, which is crucial for maintaining communication capabilities.
Energy generation and management are critical for the PULSE Satellite’s operation, achieved through surface-mounted solar panels strategically placed on its exterior. These panels are arranged to maximize sunlight exposure during orbit without obstructing other components, such as the deployable antennas. Thoughtful cable routing and carefully designed overhangs further enhance energy efficiency and maintain structural integrity, ensuring optimal functionality.
The internal assembly of the PULSE Satellite is meticulously organized to maximize space efficiency and functionality. Subsystems are securely mounted within the frame using modular brackets and supports, ensuring stability during launch and operation. Careful consideration is given to thermal management, with components positioned to facilitate heat dissipation and maintain optimal operating temperatures. This assembly approach allows for seamless integration of payloads and subsystems, contributing to the satellite’s overall reliability and performance.
The development process of the PULSE Satellite involved extensive simulation and rigorous testing to validate performance under space conditions. Finite element analysis (FEA) simulations evaluated the structure’s resilience to launch vibrations, thermal fluctuations, and other environmental stresses. Prototypes of the deployment mechanism underwent vibration and thermal vacuum tests to simulate orbital conditions, confirming the reliability of the nichrome-wire burn circuit and microswitch system. These efforts ensured that the satellite would perform as intended in the challenging environment of space.
To balance functionality with weight constraints, advanced mass optimization techniques were employed. Components were iteratively analyzed and redesigned to minimize excess material without compromising structural integrity or performance. This approach was instrumental in achieving the satellite’s lightweight yet robust design, allowing for the integration of essential subsystems while maintaining compliance with PocketQube standards.
The PULSE Satellite’s design opens the door to a wide range of applications, including Earth observation, communication, and scientific research. Its cost-effective and efficient design makes it particularly appealing to educational institutions, research organizations, and commercial entities seeking affordable access to space. The project exemplifies the potential of small satellites to contribute to diverse scientific and technological advancements.
Beyond its immediate mission, the PULSE Satellite serves as a benchmark for future small satellite designs. Its lightweight structure, reliable deployment mechanism, and meticulous optimization processes offer valuable insights for developing more advanced CubeSats and PocketQubes. These lessons can drive innovation in low-cost, high-performance satellite missions, expanding opportunities for space exploration and research.
The PULSE Satellite epitomizes the synergy of innovative engineering and practical design principles. By prioritizing reliability, efficiency, and cost-effectiveness, the project achieves a robust and lightweight satellite ready for deployment. Rigorous testing and validation ensure its readiness to meet the challenges of space, establishing a new standard for small-satellite missions and paving the way for future advancements in the field.