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Rexus User Manual

1. iii 39 THERMAL DESIGN OF EXPERIMENTS ii 40 6 1 The REXUS Thermal EIEVIFODPDCRBL sero re ot ci 40 ON 40 Gu Countdown Phase sl io 40 E 40 Ob Post ElishpPhaseso o es 40 6 2 REXUS Thermal Requirements eee ar e esee ie Ne tae 41 6 2 1 Heating of the Outer Structure ti as 41 6 2 2 Temperature at the Feed Through Cable i 41 6 2 3 Heat Radiation in the Module Interfaces 41 6 2 4 Convection between Connecting Modules seen 41 ELECTRICAL DESIGN OF EXPERIMENTS ii 42 LI System Overview nee ee 42 7 2 Radio Frequency COTS LEGALS hl ie los SILLA 42 ESEMPIO 42 Ve Teleme Syste alari laeta ot b a etat pedido 43 7 3 TelScormmandzs A A eae Pasa asad eens 43 7 6 REXUS Experiment Interface Description una 43 7 6 1 Experiment Interface Connector inda aaa 44 1 62 Telemetry Interface aeronavale 44 102 Te lcommand Ai A dd 45 Tio E 45 409 amp hliargine tac s osos boo eere po taxes daten equ E 46 7 0 0 Control Int etfabes unies IIS 46 TOT AMECA 47 7 7 Interface Description on IO nia 48 Ps ANA A DET 48 79 Balice ae sn ehe 49 2 10 Additonal Ubicato a 50 7 1021 Orientation 3 E BE GS 50 10 11 7 10 2 Electrical Umbilical Provided by Experiment Teams 50 7 10 3 High Power Connections cha keins 50 7 10 4 Ground Support Equipment Umbilical Interface
2. 50 7 11 Electro Magnetic Compatibility i 51 7 12 System Grounding ined la aaa palesa 52 GENERAL DESIGN CONSIDERATIONS tene iuter i tee Sa ews 54 8 1 Experiment AC CESSIBIITE Vt s eo bees ER reb eee o moUi alert 54 52e Availability of Pistelli ela 54 8 3 Experiment Construction aaa 54 od Redundaney nee 54 8 5 Mass and S zeC onsideralions isn 54 5 0 Effectiveness of Testin eretta 54 SIRO RR S E E 55 ENVIRONMENTAL TESTS PERFORMED BY THE EXPERIMENT TEAMS 56 Sl Macoun Ted A mm 56 9 2 Thema Testa line ibi e M LL 56 93 Mibrabon Testos nnii ar SE 57 9 3 1 Acceptance Levels Vibration u a un 58 9 3 2 Qualification Levels Vibration 59 Random vibration qualification test levels for axes X Y and Z 60 PRE CAMPAIGN ACTIVITIES aaa 61 10 1 Esrange Safety Board ESB denen an ai 61 10 2 Campaign Requirements Plan CRP Flight Requirements Plan FRP 61 10 3 Experiment Acceptance Review EAR ieri 61 10 3 1 Experiment Status by Delivery eene 61 10 3 2 Experiment Incoming Inspection eese 62 10 4 Payload Assembly and Integration TestS eene 62 TU AT Payload Assembly zaia ae 63 10 4 2 Electrical Interface Test uao eei me ie erede 63 10 4 3 System Electrical Test 1 and EMI Check esee 63 10 4 4 Flight Simulation Test emet e esee eaten e eina oen 63 10 4 5 Mass Pro
3. REXUS User Manual EuroLauncH A DLR and SSC cooperation Abbreviations AIT Assembly Integration and Test APID Application Identifier ASAP As Soon As Possible BF Body Frame Coordinate System BNC Bayonet Neill Concelman CD Countdown CDR Critical Design Review CPU Central Processing Unit CRP Campaign Requirements Plan CRC Cyclic Redundancy Check CRP Campaign Requirements Plan CSM Checksum DLR Deutsches Zentrum fiir Luft und Raumfahrt The German Aerospace Centre DTM Operation Call sign for DLR telemetry station EAT Experiment Acceptance Test EAR Experiment Acceptance Review ECSS European Cooperation for Space Standardization EGSE Electric Ground Support Equipment e g Service Module control box EMC Electro Magnetic Compatibility EMI Electro Magnetic Interference ESA European Space Agency ESD Electro Static Discharge ESRANGE Esrange Space Center ESR ESRANGE ETM Operational Call sign for Esrange telemetry station EXP Experiment E Box Electronics Box FAR Flight Acceptance Review FEC Forward Error Correction FET Field Effect Transistor FRP Flight Requirements Plan FRR Flight Readiness Review FST Flight Simulation Test GMSK Gaussian Minimum Shift Keying GND Ground GPS Global Positioning System GS Ground Station GSE Ground Support Equipment HCD Hot Countdown HK House Keeping H L Hard Line H W Hardware ICD Interface control document IH Igniter Housing REXUS User Manual I F IPR
4. yeci and zecr The fundamental plane is the Earth equator The xEcr axis points towards the vernal equinox The yecr axis points to the North Pole This coordinate system is not rotating It is assumed to be inertially fixed in space see Figure A 14 1 Equatorial Plane X Fixed HS Figure A 14 1 Earth Centered Inertial System ECT Ref 12 A position in the ECI System can be defined in Cartesian coordinates xec 1 yECI ZECI or in polar coordinates Right Ascension a Declination geocentric distance r Ref 11 The transformation between the coordinates is done with following equation Page 79 REXUS User Manual EuroLauncH x cos Cosa r y r cos sina Eq A 1 Ref 11 Z sind a arctan gt x Eq A 2 Ref 11 arctan Xx q Eq A 3 Ref 11 E 2 2 2 di i ae Eq A 4 Ref 11 As with the heliocentric coordinate system the equinox and plane of the equator move very slightly over time so a truly inertial reference frame for the Earth is impossible to realize An inertial coordinate system can almost be achieved if it refers to a particular epoch and it is specified how the vectors are transformed to and from this time Calculations that transform vectors to and from this epoch are usually called Reduction Formulas The ECI reference system for the REXUS data is the J2000 0 system This has been used since 1984 The xecraxis points in the direction of the mean vernal equinox
5. EuroLauncH A DLR and SSC cooperation This document remains our property and should not be copied without our written allowance Nor is it permitted to show or give this document to a third person Contravention will be prosecuted with the support of existing law REXUS User Manual Document ID RX_UserManual_v7 11_08Jan14 doc Version Issue Date Document Type Valid from 7 11 08 Jan 2014 Spec 08 Jan 2014 Current version issued by Simon Mawn Contributors Please see Change Record for a list of contributors Current version approved by Alexander Schmidt Distribution Change Record Version Date Changed chapters 2007 02 07 Text TBD is in italic and underwritten 2007 11 29 H Hellmann A Stamminger 2007 11 30 2007 12 05 2007 12 05 2008 06 10 2008 09 24 AII 2008 10 01 All 2008 12 11 All 2009 03 02 All 2009 04 07 All 2009 11 11 1 2 4 1 1 7 x 2009 12 04 AII 2010 08 30 3 5 5 4 6 7 4 7 6 7 8 11 5 11 8 12 7 12 8 12 9 2010 12 23 4 3 2 9 3 1 2 5 1 Siegl 2011 08 31 7 6 4 EuroLaunch logo Siegl 2012 06 29 lx minor edits 7 x Pinzer M Fittock Persson A Stamminger Persson ooo Persson Inga Inga Persson Page Persson Pinzer Fittock Fittock Ee Eum Hoe SS updates to electronics information 2012 06 29 Edits throughout Kinnaird document for clarity 3 4 1 timetable updated 4 3 2 graphs from flight replaced calculated trajectories 2
6. REXUS User Manual EuroLauncH 10 4 1 Payload Assembly The experiments other modules and subsystems will be mated to the payload in due order All the mechanical and electrical interfaces will be checked and tested systematically during the assembly 10 4 2 Electrical Interface Test The electrical interface test will verify the compatibility of the interfaces and the functioning of the hardware concerned Interface compatibility for critical signals protection automatisms and voltage regulations will be checked systematically during assembly Detailed procedures must be defined for each individual module or subsystem This test is performed by EuroLaunch 10 4 3 System Electrical Test 1 and EMI Check These tests shall be performed with all flight hardware electrically operational and as far as possible operating in flight configuration Telemetry transmission will be done first via cable and then via the telemetry transmitter All signals will be verified at the telemetry ground station All subsystems shall be monitored via the dedicated Ground Support Equipment GSE These tests are performed by EuroLaunch together with a representative from each student experiment team 10 4 4 Flight Simulation Test This test shall be performed with the payload in flight configuration as far as possible The test procedure shall include the countdown procedure list and follow the nominal countdown timetable This test is performed by
7. Ground Range m Figure 4 7 Altitude vs Ground Range for Previous REXUS Missions Page 30 REXUS User Manual E UROLAUNCH A DLR and SSC cooper MECHANICAL DESIGN OF EXPERIMENTS A typical configuration of an experiment module is shown in Figure 5 1 and Figure 5 2 Different types of mechanical interfaces between the experiment deck and the outer structure are possible EuroLaunch will assist experiment teams to define suitable mounting positions joints and screws It is a requirement that the experiment modules are either made gas tight or equipped with venting holes For experiments requiring late access hatches in the outer structure are used The integration of the samples must then be made prior to vehicle arming which starts at T 40 minutes External cooling liquid gas may be supplied by gas umbilical up until launch Outer structure Figure 5 1 Experiment Module 5 1 Page 31 REXUS User Manual Figure 5 2 REXUS Nose Cone Experiment Underneath Ejectable Nose Cone Outer Structure The baseline for the mechanical design is that the outer structure is made of 14 diameter 355 6 mm 4 mm thick 120 220 or 300 mm long aluminium cylinder modules EN AW 7020 T6 blue anodisation The mass of the modules vary depending on the exact configuration required These modules are normally supplied by EuroLaunch respectively ZARM For experiments beneath the nosecone it is a 14 4 1 Ogive n
8. If you require additional information on the REXUS system please contact the EuroLaunch project manager or the system engineer of the current project 1 1 REXUS User Manual Definitions Page 10 EuroLauncH A DLR and SSC cooperation The REXUS system consists of the following components according to the EuroLaunch definition REXUS Esrange Facilities Ground Support Equipment GSE Electric Ground Support Equipment EGSE Rocket Motor Payload Subsystems Scientific Payload The complete integrated vehicle to perform the flight Equipment used to monitor and control the vehicle during flight and telemetry receiving equipment REXUS supporting systems and equipment on ground Equipment used to control and communicate with various modules during tests and flight The part of REXUS giving the accelerating force Experiment modules and all EuroLaunch subsystems All systems required for flight control recovery and telemetry All experiment modules including the experiments Experiment Module Experiment equipment and its outer structure Hierarchy REXUS System LVehicle HPayload LScientific Payload Experiment Modules Lpayload Service Subsystems ETM TC Systems Power System LSensors LRadio System LRecovery System LRocket Motor LGround Equipment LEsrange Facilities LExperiment Module Ground Support Equipment LService System Ground Support Equipment 1 2
9. s centre Page 83 REXUS User Manual EuroLauncH ROEARUI North Pole Figure A 14 5 Vehicle Carried Vertical Frame As already mentioned velocity is given in this coordinate system and the Flight Path Angle y and the Heading Angle f can directly calculated with the following equations y atn Eq 14 11 y ty north east B anf Veast V north Eq 14 12 The next figure shows the orientation of the angles Figure A 14 6 Flight Path Angle and Heading Angle Page 84 REXUS User Manual EuroLauncH B APPENDIX B Esrange Safety and Security Compliance Confirmation Rocket This document clarifies the basic safety and security conditions for the campaign UU at the Esrange Space Center This document shall be signed by the customer s range user s prme contractor s Mission Manager Project Manager and by the Esrange Project Manager One copy of this document and of the Esrange Safety Manual ESM EUA00 E538 is submitted to the customer s Mission Manager Project Manager Swedish law and Swedish safety and security regulations apply to all activities at Esrange The Esrange Safety Manual provides safety regulations and criteria associated with launching of sounding rockets UAV s and stratospheric balloons and must be followed by all parties involved Temporary and complementary regulations may be issued at any time via the Esrange Project Manager and conveyed to the Mission Manager P
10. 3 5 2 Campaign Requirements Plan Flight Requirements Plan 20 3 5 3 Flight Report Documentation aa see 21 REXUS SYSTEM usos bi tpi en Ud led um MT Mende 22 dl REIS Vehicle nie 22 4LlL ServceModule intere ak 22 4 1 2 Mate COMO it A rei i aic visu pi 23 4 1 5 Recovery Module aiar OE ST iaia 24 414 Homme Ald A O grillen 24 AVS EV Channel susanne 24 4 2 Body Frame Coordinate System aan aa 24 4 3 Performance and Flight Sequence unse alan 25 431 Nominal Tajo seen aan 25 4 3 2 Graphs of typical trajectory ciali 26 MECHANICAL DESIGN OF EXPERIMENTS ccss cccsssceesssceesseceessseesssseeees 30 5 1 CSE Sale A aE Eea SEa 31 5 2 D SUB Brake illo salaria 34 A aaa 36 53 1 Late Access Hatch ss sciura lone oi de EM ili 36 5 3 2 Inflight Actuated Hatches aui qoe retain ae 36 5 4 Exhaust Openings ice ies te id ds 37 2 Venting Holst De E 37 5 6 Ejectables and Free Falling Unit cnica 37 5 7 External Skin Mounts oen tea eee 37 5 5 Useof Rlaids within Modules aa sa na an ei 38 5 9 Dimensioning Loads during Launch Flight and Recovery 38 A A ra 38 3 92 AA toV NM tI DEI US Ata duet idis 38 3 9 3 Landing Velocity iii za kl 38 5 10 Mechanical Retroaction Forces from Experiments on the Payload 38 5 10 1 Vehicle Characteristics use lin is 38 5 102 Movements Ir 39 5 10 3 VibratiOns 3 5 fa Ra BEE LE e iiei 39 5 11 Mass Balance and Mass Properties
11. UROLAUNCH Figure 7 4 RS422 Interfacing Example Interface Description on Ground Space will be provided in the Scientific Office in the main building The operator of an experiment receives his experiment data via a RS 232 interface and he can control his experiment by sending commands via the same RS 232 interface over the umbilical If a recorder is onboard it can be switched on just before lift off The SOE and the SODS can be defined by the user and they are controlled by timelines on board If necessary experiments can be switched off either by telecommands or by timelines This can be performed only by the payload engineer before Lift Off Reception of experiment data Baudrate 38 4 kbit s Format 8 bits 1 start and stop bit no parity Commanding of experiment Baudrate 38 4 kbit s Format 8 bits 1 start bit and stop bit no parity A higher baudrate on ground than on board is no mistake it ensures that all data can be distributed to the users in time Of course the uplink data rate has to be the same as the downlink rate but it is not possible to continuously send data at 57 6 kbit s to the experiment see 7 6 3 TV Transmitter If a TV downlink is requested by an experiment the transmitter will be integrated in the RXSM in combination with a video multiplexer Three TV sources can currently be connected to the multiplexer During the ascent and free flight phase of the rocket the TV channel is switched to t
12. ZARM under contract of DLR Space Administration When EuroLaunch is mentioned in this document it means that all three institutions SSC MORABA and ZARM may be involved The scientific evaluation of the experiment proposals and the financial support of the students are the responsibility of the DLR Space Administration and the Swedish National Space Board SNSB in the latter case through cooperation with the European Space Agency ESA At EuroLaunch the following key positions will be assigned for every flight project e Project manager e Payload manager e Mechanical design responsible e Electrical design responsible e Telemetry TM and Telecommand TC systems responsible e Electric Ground Support Equipment EGSE responsible One person can have dual assignments Additional positions will be assigned during the campaign see chapter 12 4 The majority of the communication between EuroLaunch and the experiment teams shall pass through the project managers Flight Ticket In the REXUS flight ticket which is offered to the international student community the following services are included e General management and planning of the REXUS project e Provision of the launch vehicle and subsystems necessary for a spaceflight mission e Integration of participating experiment modules into the flight configured payload and pre flight testing of the payload TM TC flight simulation test dynamic balancing vibration te
13. by the previous REXUS missions note the designated ground range change for REXUS 5 and 6 Note dashed lines refer to predicted rather than recorded data where data is missing or corrupt 90000 Altitude vs Flight Time 80000 REXUS 5 101 7kg 80km Ground Range REXUS 6 95 1kg 80km Ground Range 70000 REXUS 7 121 7kg REXUS 8 105 2kg REXUS 9 120 5kg 60000 REXUS 10 112 3kg REXUS 12 114 18kg 50000 Altitude above mean sea level m Flight Time s Figure 4 5 Altitude vs Flight Fime for Previous REXUS Missions 90000 Altitude vs Flight Time n REXUS 5 101 7kg 80km Ground Range REXUS 6 95 1kg 80km Ground Range 86000 REXUS 7 121 7kg REXUS 8 105 2kg REXUS 9 120 5kg REXUS 10 112 3kg REXUS 12 114 18kg E 8 8 Altitude above mean sea level m y 74000 u u u aw isu iw uu am z u 23 am Flight Time s Figure 4 6 Apogee Focus for Altitude vs Flight Time for Previous REXUS Missions Page 29 REXUS User Manual EuroLauncH A DLR and SSC cooperation 90000 Altitude vs Ground Range 80000 REXUS 5 101 7kg 80km Ground Range REXUS 6 95 1kg 70000 80km Ground Range REXUS7 1217kg REXUS 8 105 2kg REXUS 9 120 5kg 8 Altitude above mean sea level m 20000 0 10000 20000 30000 40000 50000 60000 70000 80000
14. levels for axes X Y and Z 10 0 1 PSD g Hz 0 01 0 001 20 200 2000 Frequency Hz Figure 9 2 REXUS Random acceptance test level for all axes Page 59 REXUS User Manual EuroLauncH Table 9 2 Axes Frequency Level PSD Remark Longitudinal Z 20 2000 Hz 6 0 grms 0 018 g Hz Lateral X Y 20 2000 Hz 6 0 gRMs 0 018 g Hz Duration 20 s axis Remark For a flight model EuroLaunch recommends a test for 60 s axis at acceptance level 9 3 2 Qualification Levels Vibration Take note that qualification levels are not normally performed with flight hardware unless there is a possible influence on flight dynamics The levels ensure that the design is adequate and give a high confidence that failure will not occur Sinusoidal qualification test levels for axes X Y and Z 10 Acceleration g a 0 1 i 10 100 1000 10000 Frequency Hz Figure 9 3 REXUS Sinusoidal qualification test level for all axes Table 9 3 Frequency Level Sweep Rate Remark 10 50 Hz 0 124 m s 4 87 in s 4 octave per minute 50 2000 Hz 4 0 g 4 octave per minute Input to payload during lateral sinusoidal vibration must be limited during first bending mode via dual control accelerometer at CoG of the payload This is done to avoid exceeding the maximum bending moment at the base of the payload Limited Bending Moment 11300 Nm Remark Usually
15. may be given but not LO As a result of the electric design the LO signal is distributed to all LO signal pins in parallel This means all LO pins are electrically interconnected This requires a special treatment when connecting this signal see below Waveform information for_signals will be added to this document in the future In the meantime if it can be seen that this is required for an experiment The experiment team should contact EuroLaunch to request this information 7 6 7 Interface Suggestions Lift Off Signal SOE SODS signals RXS con Figure 7 3 Interfacing Example This example uses an optocoupler to establish the interface to RXSM The important part is the relation of the primary part to the 28 V system power You can use also a FET or a transistor but always relate to the 28 V system power Never connect this signal directly to your microprocessor input Due to the fact that the LO signal is interconnected to other experiments where it is also connected to 28 V via a pull up resistor direct connection to a 5S V or 3 V device can cause damage or malfunction SOE and SODS signals are not shared with other experiments like the LO signal so precautions must not be taken there RS422 signals On the RXSM E Box end downlink there is a 1 kQ resistor between the data lines On the experiment side uplink a 1 kQ resistor should also be implemented 7 7 7 8 Page 48 REXUS User Manual E
16. not performed by EuroLaunch Page 60 REXUS User Manual E UROLAUNCH Random vibration qualification test levels for axes X Y and Z 10 1 4 a 0 1 a 0 01 0 001 20 200 2000 Frequency Hz Figure 9 4 REXUS Random qualification test level for all axes Table 9 4 Axes Frequency Level PSD Remark Longitudinal Z 20 2000 Hz 12 7 grms 0 081 g Hz Lateral X Y 20 2000 Hz 12 7 grms 0 081 g Hz Duration 20 s axis Remark For a flight model EuroLaunch recommends a test for 60 s axis at acceptance level 10 10 1 10 2 10 3 Page 61 REXUS User Manual EuroLauncH PRE CAMPAIGN ACTIVITIES Esrange Safety Board ESB Every campaign or project at Esrange has to be accepted by the Esrange Safety Board A standard rocket is normally no problem If there are hazardous items such as chemicals free falling objects lasers radiation etc included in the experiments there may be a need for further investigation This may take some time and should be done early in the design process preferably well ahead of the start of the launch campaign Campaign Requirements Plan CRP Flight Requirements Plan FRP The REXUS project manager provides Esrange Space Center as well as all parties involved in the project with the Flight Requirements Plan This document gives a complete description of the specific project including payload description a list of hazardous mater
17. stated in the input to the Flight Requirements Plan When positioning the parts or components the sensitivity to heating ESD and electrical disturbances shall be considered Connectors shall be well marked and preferably keyed 14 4 14 5 Page 77 REXUS User Manual EuroLauncH 14 3 3 Re used Items It is important to consider the complete history of any re used item by consulting the hardware logbook or former project log book to be sure that it does not include any hidden failures 14 3 4 Availability and Maintainability Spare parts for components susceptible to failure shall be available during the payload AIT and the launch campaign The design shall allow for easy and fast replacements of such components 14 3 5 Handling Storage and Packing ESD susceptible components shall be handled in an ESD protected environment Before transport the product shall be thoroughly packed to withstand the expected loads The use of a bump recorder is recommended Personnel Safety The REXUS experiments and dedicated equipment must fulfil safety requirements according to Swedish law The Swedish Work Environment Act is a general act that is backed up by special laws and regulations in different fields The Swedish work environment authority issues these regulations Special provisions apply among others to the following fields e Explosives e Inflammable material e Chemical hazards e Electrical facilities e Radiolog
18. with a diode to avoid reverse current and discharging 7 6 6 Control Interface The RXSM supplies 3 different control lines for each experiment They are implemented as open collector outputs with the capability to sink a current of maximum 50 mA from ground for each channel The 28 V GND is also structure ground An active signal means low impedance to ground inactive means high impedance to ground The user should connect either an optocoupler device or a relay to make this signal available for his experiment If using a relay the user is responsible for including a clamp diode close to the coil of the relay Available control lines e Start of Data Storage SODS This control line can be issued by time line during flight or it can be initiated by the EGSE system via umbilical e Start of Experiment Stop of Experiment SOE This control line can be issued by timeline or by command during flight e Lift Off LO This signal is derived from the extraction of the umbilical connector from the Service Module when the rocket leaves the launcher This is also a reset of the internal millisecond counter of the RXSM All timeline events are correlated with this event T 0s During bench testing it is possible to simulate the lift off condition but not when the rocket is mounted on the launcher Test countdowns will usually be stopped before the Page 47 REXUS User Manual E UROLAUNCH lift off event so in this case SOE SODS
19. 012 08 30 5 updated and Fittock information added 9 3 edited 2012 09 03 Minor edits 1 1 3 Inga 4 3 2 5 5 5 6 5 8 7 2 11 1 12 4 1 12 8 2013 01 25 4 2 Figure 4 4 Schmidt 2013 09 03 Edits throughout Newie document for clarity A 5 3 2 6 1 1 7 1 7 2 A Kinnaird 7 3 9 3 10 3 2 13 2 2013 12 17 si Schmidt M Pinzer A Stamminger 2014 01 08 9 3 S Mawn U Kaczmarczik Abstract This document has been created to aid experimenters taking part in a REXUS flight as part of the REXUS BEXUS Programme It is continually updated and developed in order to serve the experimenters and operators better It describes important information about flights for experimenters interface details design guidelines and testing Keywords REXUS manual interface EuroLaunch testing design This is not an ICD document Table of Contents 1 INTRODUCTION eisllehulnii 9 SAA O 10 172 Abbreviations iaia ail 11 1 3 Relerences scutis fauna daas area pie 14 1 4 Applicable documents ase aa aio Pe Ue ea agili 15 ALWAYS READ TED estet Deu ua lese 16 REXUS PROJECT OVERVIEW AND MILESTONES eene 18 o A ate ee eae eset cs se Duas ig se uten acon 18 32 A MM Eis 18 33 7 Experimenten s Role OA 19 3 2 Project Plannin e E ro 19 3 41 Indicative Frmetableu deo dn depo BOG e Meteo diee o 19 3 5 Experimenter Documentation Requirements eene 20 3 5 1 Student Experiment Documentation SED 20
20. 2 7 Science Center Operations and Communication eene 13 om Recovery RNC P Nessie en 74 POST LASUNCH ACTDVUTIBS ssaa 75 15 1 5 Pose ich Ne i o galla lora E E meses tens 75 13 2 Disassembly of the payloddiso csi joo torio a RR otis 75 13 3 Camparen Te O ee 75 EXPERIMENT QUALITY ASSURANCE 76 DET A cet hed eredi a agi e leto he ia 76 142 Components uaar iaia agi 76 14 3 Additional Quality Tops ei 76 14 3 1 Procured Products and Audits eei tene ras 76 14 3 2 Manufacturing Control and Inspection eee 76 14 3 3 Rerused Items auspicia ld 77 14 3 4 Availability and Maintainability eene A 14 3 5 Handling Storage and Packing sse 74 14 4 Personnel Salety aieo nose fo rl an T4 14 5 Safety at Estanse Space Center an ee Da ode aa 71 COORDINATE SYSTEM DEEINTTION essen 78 A Earth Centered Inertial System ECL sso eier 78 A 2 Earth Centered Earth Fixed ECEF eese 719 A 3 World Geodetic System 1984 WGS84 sse 80 A 4 Local Tangential Coordinate System LTC esee 81 A 5 Vehicle Carried Vertical Frame VCVF 82 APPENDIX Billie Li ROERO 84 Page 9 REXUS User Manual EuroLauncH INTRODUCTION The REXUS Rocket borne EXperiments for University Students programme is an annual sounding rocket programme for university students which aims to provide practical ex
21. EuroLaunch together with a representative from each student experiment team It is important that any modifications made to hardware or software after the Flight Simulation Test are restricted to a minimum Non conformances discovered during the test can of course be corrected but care must be taken to verify that no further malfunctions are induced by the correction All corrections after the FST shall be documented and reported to EuroLaunch Basic Procedure e The experiment payload shall be integrated and in flight configuration The Ground Support Equipment GSE shall be connected via the umbilical The telemetry and telecommand checkout system shall be connected via the interface harness e Module data shall be supervised and recorded during the test e A nominal realistic countdown procedure shall be followed including at least one payload checkout Switching between external and internal power shall be done at the nominal time T 2 minutes Page 64 REXUS User Manual EuroLauncH e At lift off the umbilical shall be disconnected and the payload shall be controlled via TM TC The experiment sequence shall be as close as possible to the flight sequence It is also useful to perform a test with unexpected performance and to practise possible countermeasures Examples of abnormal occurrences are e Interruption in internal power supply e Reset of onboard processor e Malfunction of subsystems e g illumination
22. Hexagon Socket Head cap screw ISO 4762 DIN 912 M5 X 16 mm Material Stainless A2 The torque moment for the M5 screws is 6 5 Nm 5 2 Page 34 EuroLauncH REXUS User Manual To Figure 5 6 Experiment Modules D SUB Brackets In each experiment a standard EuroLaunch D SUB Bracket see Figure 5 6 Experiment Module should be mounted to enable assembly of scientific payloads It is to be located at 180 degrees in the module this is opposite the groove cut in the module for the zero degree line which is represented in the CAD files found on the teamsite It should sit 20 mm below the bottom of the RADAX flange at the top of the module Above and below the space should be left clear so that cables can be easily passed through and mounted to the walls 1 Page 35 REXUS User Manual Figure 5 7 Standard EuroLaunch REXUS D SUB Bracket In addition a clear feed through should be left through the experiment wide enough to pass through up to 4 D SUB 15 connectors this shall include a cable feed through hole cut through the module Figure 5 8 REXUS Bulkhead 5 3 Page 36 REXUS User Manual E UROLAUNCH Hatches 5 3 1 Late Access Hatches Hatches for late access should be oriented so that access is possible when the payload is on the launcher Hatches for late access should be oriented so that access is possible when the payload is on the launcher i e well away from the 0 degree line Hatches
23. LB LO ET M M MFH MORABA MRL MTR NCR NSROC PA PAL PCM PDR PE PI PSD PST PTS P L QA REXUS RF RFW RNRZ RXSM SAF SCI SDC SED SMC SNSB SODS SOE STW S W TBC TBD TC TCU TM TV Page 12 EuroLauncH A DLR and SSC cooper Interface Integration Progress Review Launcher Box Lift Off Signal Local Time Minute Month Mission Flight Handbook Mobile Raketenbasis DLR Medium Range Launcher Mid Term Review Non Conformance Report NASA Sounding Rocket Operations Contract Public Announcement e g video monitors Phase Alternating Line Pulse Code Modulation Preliminary Design Review Payload Engineer Principal Investigator Power Spectral Density Payload System Test Swedish Post and Telecom Agency Payload Quality Assurance Rocket borne Experiments for University Students Radio Frequency Request for Waiver Randomized NRZ a signalling modulation REXUS Service Module Safety Officer Project Scientist Serial Data Commands Student Experiment Documentation Service Module Commands Swedish National Space Board Start Stop of Data Storage Signal Start Stop of Experiment Signal Student Training Week Software Time before and after launch noted with or To Be Confirmed To Be Determined Telecommand Telemetry Central Unit Telemetry Television REXUS User Manual EuroLauncH A DLR and SSC cooperation UTE User defined Timer Event Signal WGS84 World Geod
24. an important point that is often overlooked by experimenters It is in your interest that items such as switches battery packs and cable connections are easy to access Considering access to fasteners is also worth the time Availability of Parts A major issue for many experimenters is late delivery and procurement delays Rather than merely basing a design on parts from catalogues ensure that they are available this can save a lot of time and money for experimenters Avoid designs based on hard to procure items or irreplaceable items where possible Experiment Construction Costs Consider enforcing a three quote minimum on components where possible this is often not possible due to the specialized nature of items When designing remember that the cost for machining can differ greatly depending on early design decisions Avoid close tolerances wherever possible not only is it cheaper but it can save time with assembly Remember to use experience and judgement the cheapest items are not always the best selection Redundancy Redundancy is desirable especially where there are safety or failure risks It is not as simple for mechanical as electrical but it should be considered during the design process Redundancy can be simply achieved by separate battery packs multiple switches check valves and other solutions Mass and Size Considerations Minimizing mass is commonly overlooked by experimenters However keeping mass low where po
25. and the Zecr axis points in the direction of the mean rotation axis of the Earth on January 1 2000 at 12 00 00 00 TDB which corresponds to a Julian date JD 2451545 0 A 2 Earth Centered Earth Fixed ECEF If the geocentric coordinate system rotates with the Earth it results in the Earth Centered Earth Fixed Coordinate System abbreviated as ECEF The main difference with this system is that the primary axis is always aligned with a particular meridian The xgcer axis points toward the Greenwich Meridian which is defined as longitude 0 This coordinate system is rotating The position of an object is defined with the geocentric Latitude gc which is measured positive in the direction North of the equator the Longitude 0 which is measured positive in the direction East from the Greenwich Meridian and the distance d from the Earth s centre Ks COS P COS O r Vecer d coso sind Eq A 5 ECEF ZECEF SIND Page 80 REXUS User Manual E UROLAUNCH Figure A 14 2 ECEF Coordinate System A 3 World Geodetic System 1984 WGS84 The global reference system World Geodetic System 1984 WGS84 is used for the REXUS GPS position data The reference ellipsoid is rotation symmetric and every plane cuts the ellipsoid to an ellipse with the flattening fe which is defined with the relative difference of the equator and pole radius R4 R fa Eq A 6 Ref 11 Ro The WGS84 Ellipsoid has a flattening of fe Kog2s7223s63
26. and the equator radius Re is 6378137 m Ref 11 The Earth s eccentricity es can be calculated with the following equation es JA 0L fa Y Eq A 7 Ref 11 The position of the Rocket is given in geodetic coordinates relative to the reference ellipsoid The geodetic longitude 0 corresponds to the geocentric longitude Unlike the geocentric latitude s which is the inclination of the position vector to the equatorial plane the geodetic latitude ga describes the angle between the equatorial plane and the normal to the reference ellipsoid It is positive to the North and negative to the South The difference of geodetic and geocentric latitude is shown in the following figure Page 81 REXUS User Manual E UROLAUNCH Local Tangential Plane on Ellipsoid 7 1 5e h Reference Ellipsoid Figure A 14 3 WGS84 Reference Ellipsoid The flattening of the Earth is very small because the difference between the Earth s radius at the equator and the poles is less than 22 km Therefore the difference between geodetic and geocentric latitude is 12 minutes of arc A 4 Local Tangential Coordinate System LTC This system is important for observation of the rocket from the Launcher Tracking or Radar Stations The LTC system rotates with the Earth The E axis points to East the N axis points to the North and the Z axis is the zenith that is perpendicular to the tangential plane at the observation location usually Launcher Th
27. are 6 identical interface ports available for experiments 5 of which are available for payload connection with each port providing the TM TC control wires and power A further 2 ports are available for a TV channel connection The feed through harness i e the cabling that connects your experiment to the service system will be designed and provided by EuroLaunch Radio Frequency Constraints In general for every transmitter that will be used at Esrange Space Center during a campaign information must be given to Esrange well in advance in order to receive permission to transmit RF At Esrange the reception of weak satellite signals might be jammed and therefore special care must be taken regarding when and how RF transmitting occurs It is also necessary to apply for frequency permission at the PTS Swedish Post and Telecom agency SSC Esrange can either apply on behalf of experiment teams or give them the information needed to make such applications Parameters such as transmitting frequency radiated power bandwidth of signal antenna and antenna pattern and modulation type are required information to have in advance The following frequencies are used in safety telemetry and recovery systems and are therefore not allowed to be used in any experiment 240 80 244 05 MHz 449 451 MHz 1575 MHz 2290 2295 MHz 2338 1 MHz Durability After integrating the payload the whole rocket is mounted on the launcher In this lat
28. ayload is normally brought back to Esrange within a few hours of launch 4 1 5 TV Channel One analogue TV channel is available for video transmission from one experiment The TV signal should be a standard PAL B G with 1 Vss at 75 ohms To connect this signal to the RXSM a BNC connector should be used Body Frame Coordinate System For REXUS the Body Frame Coordinate system BF is used for the orientation of rocket components and experiments Drawings of components and experiments should respect this axis definition Accelerations are measured with the accelerometers referring to this coordinate system The longitudinal axis is the roll axis zer which along with the pitch axis Xpr and the yaw axis ysr build a right hand system Yer Yaw 90 Roll b M Pitch N Xp Figure 4 4 Definition of the REXUS BF System 4 3 Page 25 REXUS User Manual EuroLauncH The BF angle velocities q r and p and the Roll momentum L the Pitch Momentum M and the Yaw momentum N are defined in Figure 4 4 The origin of the system is located at the interface between the motor adapter and the payload on the longitudinal axis of the REXUS vehicle Performance and Flight Sequence The performance of the REXUS rocket may be adapted to the respective mission requirements In the following tables the flight sequence and g levels from a typical REXUS flight with an Improved Orion motor are presented 4 3 1 Nominal trajectory The no
29. cedure e The experiment shall be placed in a thermal chamber The Ground Support Equipment GSE shall be connected via the umbilical The telemetry and telecommand checkout system shall be connected via the interface harness e Experiment data shall be supervised and recorded during the test e The temperature shall preferably be measured at several places in the experiment e Low temperature test Adjust the temperature in the thermal chamber to 10 C When the measured temperatures in the experiment have stabilised perform a functional test flight sequence Be aware of condensation problems if the test is performed at normal humidity 9 3 Page 57 REXUS User Manual EuroLauncH e High temperature test Adjust the temperature in the thermal chamber to 45 C When the measured temperatures in the experiment have stabilised perform a functional test flight sequence During the transition from low to high temperature the experiment shall be operating and data shall be recorded Vibration Test A vibration test shall be performed to verify the individual experiment can withstand the vibration loads during the launch of REXUS It is the responsibility of the experiment team to perform this test For REXUS acceptance tests are nominally performed on all experiments Where an experiment can influence the scientific payload it is required to perform an acceptance test Where an experiment can affect flight dynamics it is req
30. ch launch team 11 4 2 Assembly and Checkout of Payloads Payload assembly and preparations are conducted by the REXUS project manager together with EuroLaunch staff Working space in the launching area will be allocated by Esrange Flight Simulation Tests FST The payload will be ready for the final Flight Simulation Tests FST after successful results in the checkouts Umbilicals shall be connected and the payload shall preferably be in a vertical position Each module shall be monitored and controlled by the module ground support equipment When all modules are operating nominally a short countdown and flight sequence will be performed This test can be repeated many times if found necessary or desirable to do so All telemetry and telecommand signals will be recorded in the telemetry ground station during the test At a minimum two tests will be performed in preparation for the countdowns One with lift off signal and one without the lift off signal will be given by removing the umbilical During these tests the experiment operators will be in the Science Centre and should treat the tests as not only a test of the experiment but also of the procedures and behaviour that should be conducted during countdowns Not only does this help in preparing for launch but also makes the testing easier and less stressful for everyone involved Consider for your design that this test can be operated with ease and without access and will not
31. e phase before lift off experimenters do not have access to the payload any more During this phase there will be more tests of the whole system which means that the experiments are turned on and off several times Finally there will be one or more test countdown s Experiment teams should make sure that their experiments have enough battery memory chemicals etc to cope with this in addition to the complete flight During the test countdowns the testing signals LO SOE SODS may be given at any time in any order Experimenters should be sure that they can cope with these signals and if necessary implement a testing state software or hardware to avoid the need to access their experiment 7 4 7 5 7 6 Page 43 REXUS User Manual EuroLauncH Telemetry System The REXUS telemetry system consists of the TM master board located in the E Box of the RXSM and data sources distributed in the experiment part of the payload All the data streams are multiplexed to a PCM data stream The PCM Biphase output from the main encoder modulates an S band transmitter providing the ground link The overall data rate of this PCM downlink is 500 kbit s The interface between the TM master and each user in the TM system is implemented using an asynchronous serial link connection The whole packed PCM downlink is equipped with a forward error correction FEC which minimizes data loss Data losses are expected during the launch and the re e
32. e upcoming activities are discussed An example campaign schedule is shown below Table 11 1 Example campaign schedule Date Action Day 1 Start of campaign Safety briefing Day 1 3 Preparation of experiment modules service systems and recovery systems Day 4 6 Payload assembly Flight Simulation Tests FST Mating payloads with motors Day 6 Flight Readiness Review FRR Day 7 Rocket 1 roll out to launcher and test countdown Day 8 Pre flight meeting Rocket 1 Hot countdown Day 9 Rocket 2 roll out to launcher and test countdown Day 10 Pre flight meeting Rocket 2 Hot countdown Day 11 12 Reserve days Page 66 REXUS User Manual EuroLauncH Description of Esrange Space Center All the necessary information for a user of Esrange can be found at http www sscspace com products services rocket balloon services launch services esc Its main content is Range description capabilities layout environment Range administration communications accommodation freight supplies Safety regulations Instrumentation telemetry tracking observation scientific Operations assembly checkout flight control recovery requirements procedures Satellite facilities Safety Safety always comes first at Esrange Before the start of a campaign a safety briefing will be held It is mandatory for all visiting personnel to attend this briefing 11 2 1 Additional Es
33. e 1 356 mm Rocket Fin Service Ejectable Module Experiment Ejectable Recovery sent Module Tailcan Nosecone r 5 6m Figure 4 1 REXUS Standard Configuration A typical configuration is shown in Figure 4 1 Each configuration is designed to optimise vehicle and experiment characteristics 4 1 1 Service Module The objectives of the Service Module are to establish the communication between the ground and the experiments and to control the experiments Furthermore the Service Module monitors the quality of the ambient conditions the flight parameters acceleration angular rates and the housekeeping data It also delivers power to the experiments The Service Module consists of two sections The first one contains the electronic part of the Service Module E Box while the other devices such as RF parts GPS sensors and batteries are mounted on the bulkhead of this module The Service Module has four main electrical interfaces to its environment tothe EGSE via umbilical to the experiments recovery GPS system to the ignition unit separation unit and yo yo system to the ground via RF links by the PCM and the Video transmitter Page 23 REXUS User Manual EuroLauncH Figure 4 2 REXUS Service System RXSM Rate Sensors Attitude Control Processor Recovery Interface Boar ds Telemetry Transmitter Umbilical _ _ Telecommand Hardlines Accelero Rate R
34. e a need for further investigation by the Esrange Safety Board This may take some time and should be done early in the design process Durability of your experiment During the pre flight tests and the countdown the experiments will be turned on and off several times over the course of many hours and multiple days Make sure that there is enough battery memory etc to survive these activities in addition to that which is required for the flight Spin and balance Before the start of the campaign the rocket will be balanced during the Environmental Tests After this there will not be any changes permitted in the payload configuration that could result in changes in mass inertial moment or balance Transceivers All equipment that emits or receives RF must have Esrange permission to do so Radio Frequency interference test and flight simulation After the RF test it is not permitted to make any changes to the experiments before flight If you miss this test during the campaign preparation phase it may be necessary to remove your experiment or fly the rocket with your experiment turned off If your experiment disturbs any of the flight systems it will not be flown at all Weather constraints It is not possible to guarantee a launch during any specific week due to weather constraints Make sure that your experiment can be operated by Esrange staff in case the launch is postponed beyond the date when you have to leave Planning I
35. e possible holds The experiment teams ground equipment will be situated in the scientific office in the main building REXUS User Manual Page 71 EuroLauncH 12 5 1 CD List The schedule below indicates standard countdown actions relative to launch T 0 The final CD list will be issued during the pre flight meeting Time H M Action 2H30 1H35 1H20 1H15 1H 45M 20M 15M 10M 5M 3M30 1M45 1M 40S 25S 10S 10S 1M FIRST HIGH ALTITUDE BALLOON DECISION TO START COUNTDOWN START OF COUNTDOWN CHECK LIGHTS AND COMMUNICATION END OF RADIO SILENCE SWITCH ON PAYLOAD TRANSMITTER AND TRANSPONDER AND START HORIZONTAL P L CHECK PAYLOAD TEST COMPLETED PAYLOAD TRANSMITTER OFF RADIO SILENCE IN THE LAUNCH AREA CHECK FIRING LINE LEDEX SYSTEM ARM AND ELEVATE VEHICLE CLEAR PAD SIREN ON LEDEX SYSTEM CHECKED VEHICLE IS ARMED AND ELEVATED PAD IS CLEAR END OF RADIO SILENCE SWITCH ON PAYLOAD PAYLOAD TEST COMPLETED PAYLOAD TRANSMITTER OFF RADIO SILENCE IN THE LAUNCH AREA END OF RADIO SILENCE AUTHORIZATION TO SWITCH ON PAYLOAD ARM LEDEX FIRING LINE SEND QUESTION LIGHTS VOICE COUNT EVERY MINUTE FIRING LINE LEDEX ARMED PAYLOAD ON INTERNAL TAPE RECORDERS ON VOICE COUNT EVERY 10 SECONDS SEND ANSWER LIGHT AUTHORIZE LAUNCHING VOICE COUNT EVERY SECOND LIFT OFF VOICE COUNT EVERY 10 SECONDS VOICE COUNT EVERY MINUTE UNTIL 6 M 12 6 REXUS User Manual Page 72 EuroLAuNcH Com
36. e to the experiment modules Mechanical Retroaction Forces from Experiments on the Payload An estimation or measurement of the induced acceleration or vibration levels of each experiment shall be presented to EuroLaunch at least four months before launch 5 10 1 Vehicle Characteristics Momentum wheels cavities partially filled with liquids ejectables free flying units etc will only be accepted after a successful analysis of the impact on the vehicle performance 5 11 Page 39 REXUS User Manual EuroLauncH 5 10 2 Movements Any movements of components or samples in the module can disturb the payload conditions These disturbances shall be kept to a minimum for instance through counteracting mechanical devices or symmetrical gas exhaust openings 5 10 3 Vibrations Vibrations induced by movement of components in the payload will also cause disturbances to the flight conditions The vibration levels generated in the module shall be kept as low as possible As a rule of thumb the module produced vibration levels should be lower than 5x10 0 25 Hz This level changes from flight to flight and depends on the experiment modules sensitivity to vibrations Mass Balance and Mass Properties The centre of gravity of each module shall be as close as possible to the longitudinal axis It is not necessary to carry out mass balancing of each module or to add ballast weights since the total payload will be mass balanced ther
37. eby saving total ballast weight This work is performed by EuroLaunch The accuracy should be as follows Total mass 0 5 kg Moment of inertia Ix 0 1 kgm ly 0 1 kgm L 0 1 kgm Centre of gravity X 20 mm Y 20 mm The mass of the modules should be kept to a minimum to ensure the best possible performance of the rocket 6 1 Page 40 REXUS User Manual EuroLauncH THERMAL DESIGN OF EXPERIMENTS The REXUS Thermal Environment 6 1 1 Pre Launch Phase The integration of the modules and payload is done at normal room temperature 20 5 C After integration the payload is mounted to the motors before being transported to the launcher The ambient temperature during transport can be low 30 C or lower depending on the outdoor temperature but the exposure time is short 5 10 minutes The ambient temperature is highly dependent upon the time of year for launch refer to Tu Tiempo 10 for some examples Nominally the payload is shipped fully integrated from the Bench test to the Spin and balance and then on to campaign by unheated road transport During this phase the temperature may be as low as 30 C for several hours 6 1 2 Countdown Phase Experience shows that during countdown the experiment modules tend to see an increase in temperature over time especially if long holds are required Some actions can be taken in the launch tower to improve the situation however it is recommended that temperature regulation
38. eceiver Power meters Gyros W Transmitter Figure 4 3 REXUS E Box Block Diagram 4 1 2 Rate Control A de spin system the Yo Yo can be used to reduce the stabilising spin after the launch phase This is not part of the REXUS single stage standard configuration The rocket will be de spun from approximately 4 Hz to a maximum spin rate of 0 08 Hz 30 s in a clockwise direction when viewed from the rear 4 2 Page 24 REXUS User Manual E UROLAUNCH 4 1 3 Recovery Module The recovery module is positioned in the back end of the payload and contains a drogue chute which deploys the main chute It also contains a heat shield which protects the parachutes during re entry Barometric switches initiate the pyrotechnic sequence for ejecting the heat shield and releasing the parachutes The recovery system is capable of landing payloads with the designated payload mass from approximately 100 km apogee The system is designed to decelerate from 150 m s sink velocity to 8 m s impact velocity 4 1 4 Homing Aid The vehicle is equipped with a GPS receiver from which the service module can receive time and position information during flight The GPS position is transmitted via the telemetry stream The recovery team in the helicopter can be equipped with a TM receiver in order to acquire the GPS position for quick and easy location of the payload An autonomous homing beacon transmitter is also included in the recovery system The p
39. etic System 1984 WT Walkie Talkie ZARM Zentrum fiir angewandte Raumfahrttechnologie und Mikrogravitation Page 13 1 3 REXUS User Manual Page 14 EuroLauncH References NOTE All references documents can be found on the REXUS BEXUS Team Site along with the manual The ECSS references link directly to the documents themselves firstly though in order to access the documents registration is required this is easy and free for the user 1 2 3 4 5 6 7 8 9 10 ECSS Space project management Project planning and implementation ECSS M ST 10C Rev 1 ESA Publications Division 2009 http www ecss nl forums ecss dispatch cgi standards showFile 100743 d2009030 6173339 No ECSS M ST 10C Rev 1 6March2009 pdf ECSS Space product assurance Manual soldering of high reliability electrical connections ECSS Q ST 70 08C ESA Publications Division 2009 http ecss nl forums ecss dispatch cgi standards showFile 100753 d200903061908 30 No ECSS Q ST 70 08C 6March2009 pdf ECSS Space product assurance Crimping of high reliability electrical connections ECSS Q ST 70 26C ESA Publications Division 2008 http ecss nl forums ecss dispatch cgi standards showFile 100679 d2008 11111311 54 No ECSS Q ST 70 26C 3 1 July2008 pdf SSC Esrange Esrange Safety Manual REA00 E60 ver 3B Esrange 2010 http www sscspace com file esrange safety manual pdf SSC Esrange User s Ha
40. f this uplink is 19 2 kbit s This GMSK uplink uses CRC and CSM mechanisms to avoid executing corrupt commands REXUS Experiment Interface Description Each experiment will be allocated its own standardised RXSM interface connector On this connector all communication control and power lines are implemented A D SUB 15 female connector is used to perform the interface on the RXSM side Up to 5 interface connectors are available to deliver power to control the experiments and to exchange data in both directions There is a 6 interface available but only with downlink capability no uplink Page 44 REXUS User Manual EuroLauncH A DLR and SSC cooperation 7 6 1 Experiment Interface Connector The experiment interface connector should be a D SUB 15 male type This is the connector which is connected to the Service Module socket Table 7 1 Standardised REXUS Experiment Interface Pin Name Remarks Nr E E __ ______ eee NEI pe o S SEA rmv APRA qe LLL mj Inverted Control data commands to Experiment RS 422 7 6 2 Telemetry Interface A RS 422 interface is responsible for the transfer of the experiment data to the RXSM The baud rate must not exceed 80 of the maximum data throughput The formatting failure recognizing and correction are the responsibility of the experiment teams Baud rate 38 4 kbit s standard Format 8 bits 1 start and stop bit no parity Although this asynchronous downlin
41. ge varies between 24 V and 36 V depending on the condition of the onboard batteries The experiment should be able to deal with voltage steps which may occur when switching the RXSM from external regulated to internal battery power Page 46 REXUS User Manual EuroLauncH The peak power consumption should not step over 3 A 3 A per experiment line not total consumption during switching while the mean value should not exceed 1 A mean 30 Watts The power for each experiment can be controlled by hard line commands via umbilical or if available by telecommands during flight If no telecommand after lift off is available which is standard the power can be switched by a pre programmed timeline The experiment must make provisions to limit voltage ripple fed back to the RXSM over the power line to a maximum of 100 mV If a user needs an extraordinary power system the user is responsible for the monitoring and charging of his batteries via the umbilical lines It is absolutely recommended to use always both power pins for supplying the experiment Pins 1 amp 9 and 8 amp 15 7 6 5 Charging Interface In the case of internal batteries within the individual experiment there is a charging line to provide power 28 34 V 1 A to the experiment when the RXSM is switched off This line is only for charging purposes not for operating the experiment when the RXSM is switched off in case of radio silence This line is protected
42. h Officer Vehicle VEH The Launch Officer whose call sign is Vehicle handles all personnel and equipment related to the launch He is also responsible for safety on the launch pad 12 4 7 Safety Officer SAF The safety for third parties is the major concern of the safety officer He issues permission for individuals to visit the launching area during CD This is shown by the wearing of a dedicated badge red badges for temporary visits and green badges for permanent personnel in the blockhouse during CD Countdown and Launch During the countdown phase important countdown information is displayed on PA video monitors at various locations around the launch site The nominal lift off time is planned for between 0500 and 1600 LT The launch window is determined by the payload preparation time hold requirements and the time of daylight The maximum launch window duration is 11 hours The decision to start the countdown is taken at a weather briefing immediately before the planned start of countdown This decision is based on dedicated weather forecasts and wind data obtained by a meteorological balloon released from Esrange shortly before the flight If the weather conditions are unsuitable for launching the vehicle the launch will be delayed until the flight conditions are fulfilled The general launch procedure may be subject to changes Experiments should be designed to handle not only the flight but also 3 hours of CD plus som
43. have a negative effect on your experiment In particular think about how the signals given to your experiment Lift off SOE etc will affect your performance during the test and before flight Flight Acceptance Review FAR Upon completion of payload integration tests described in chapter 10 4 the Flight Acceptance Review FAR shall be held The results from the tests shall be reviewed and problems will be discussed The objective of the FAR is to obtain system acceptance and to authorise the start of the campaign If the FAR is unsuccessful due to failure of any experiment or subsystem an agreement shall be reached whether or not to proceed on schedule Flight Readiness Review FRR The Flight Readiness Review FRR is conducted by the EuroLaunch co ordinator of the campaign after completion of experiment module preparation payload integration and Page 68 REXUS User Manual EuroLauncH A DLR and SSC cooperation test payload integration on launcher GSE installation in the blockhouse payload checkout ground support stations checkout and test countdown The purpose of the meeting is e to authorise the start of the countdown phase i e the launch e to ensure that all ground and payload service systems essential for a successful launch flight and recovery are operating nominally For this the person responsible for each system shall give a status report at the meeting e to ensure that all experiments are read
44. he one experiment On the descent or and the re entry phase the TV signal is switched to the recovery camera which will monitor the chute openings The switching time is determined by the pre programmed timeline As one of the three sources must be connected to the recovery camera this leaves only two connections available for an experiment Due to the high demand from experimenters to use the TV transmitter it is good to bring strong arguments as to why the camera is needed 7 9 Page 49 REXUS User Manual EuroLauncH During transmission of the TV signal all video is recorded A copy of the tapes recordings can be made available to the team post flight It is also possible to arrange for the video to be converted into another more convenient format This must be arranged with SSC staff and for timely delivery of the video 1t is best to arrange this in advance Additional Batteries EuroLaunch recommends using Ni Metal Hydride Ni MH batteries and has a lot of experience in using the SAFT brand of batteries on sounding rockets Other brands may be used but it is wise to contact the project manager for advice Lithium batteries should not be used if possible Recommended batteries Single use SAFT LSH Series Lithium thionyl chloride Rechargeable SAFT Li ION Nickel Cadmium or Nickel Metal Hydride series 7 10 Page 50 REXUS User Manual EuroLauncH Additional Umbilicals 7 10 1 Orientation The orientatio
45. ials experiment requirements on the launch operations tools required participants etc This is an important document used to inform all participants about the campaign The first version of the FRP will be distributed after the PDR Student Training Week Inputs are requested from every experiment team regarding interfaces telemetry power consumption and special experiment requirements Experiment Acceptance Review EAR The manufacturing phase ends with the Experiment Acceptance Review EAR following delivery of the experiment to EuroLaunch The EAR consists of e Experiment checkout functional tests e Experiment mass properties determination e Mechanical and electrical interface checkout e Electrical Interface Test EIT e Flight Simulation Test FST The EAR is performed by EuroLaunch together with a representative from the student experiment team 10 3 1 Experiment Status by Delivery EuroLaunch strongly recommends that the experiment teams conduct the following qualification acceptance tests before delivering the experiment e Electrical functional tests e Vibration tests e Environmental tests e Mechanical interface checkout 10 4 Page 62 REXUS User Manual EuroLauncH ROEARUI e Electrical interface checkout Students should ensure that there is enough time to repair or fix any problems which arise during these tests 10 3 2 Experiment Incoming Inspection All the mechanical and electrical inte
46. ical work All the above mentioned law and regulations are available at www av se inenglish lawandjustice workact The experiment team leader shall state that the module fulfils the applicable requirements and establish a list of hazardous materials which shall be communicated to EuroLaunch no later than the MTR This information shall always accompany the experiment Safety at Esrange Space Center The safety regulations that apply at Esrange may be found in the Esrange Space Center Safety Manual 4 It is a requirement that all personnel participating in the campaign shall have read the safety regulations prior to their arrival at Esrange Space Center Page 78 REXUS User Manual EuroLauncH A COORDINATE SYSTEM DEFINITION This chapter will give an overview of the coordinate systems that are used for the REXUS onboard sensors GPS and tracking systems Knowledge about the coordinate definition and transformations is important for the analysis of sensor data during the flight and for the post flight analysis The following table lists the coordinate systems used Table A 1 Coordinate Systems ECI Earth Centred Inertial ECEF Earth Centred Earth Fixed WGS84 World Geodetic System 1984 LIC Local Tangent Coordinate System VCVF Vehicle Carried Vertical Frame A 1 Earth Centered Inertial System ECI This system originates at the centre of the Earth as the name implies and is designated with the letters xec
47. ify a nominal function of the experiment during the worst case environment during countdown launch and flight Vacuum Test This test is applicable not only for experiments which will be carried out under vacuum conditions but also helps to verify that systems mainly electrical have nominal performance in the absence of convective cooling It is the responsibility of the experiment team to perform this test Basic Procedure e The experiment shall be placed in a vacuum chamber pressure below 0 5 mbar e Experiment data shall be supervised and recorded during the test e The experiment shall be operating during the lowering of the pressure in the vacuum chamber The module shall be in a similar mode as during the real ascent of the flight e After the functional test flight sequence has been performed it is recommended that the experiment is kept operating for an additional 15 minutes in order to detect any leakages or overheating problems e When testing high voltage subsystems U gt 40 V corona effects shall be searched for in the pressure interval 1 20 mbar Thermal Test A thermal test is mainly performed in order to verify a nominal function of the experiment during the worst case temperatures that can be experienced during countdown launch and flight The heating of the outer structure during ascent is normally not included or tested It is the responsibility of the experiment team to perform this test Basic Pro
48. intain professionalism and clarity in communication The Project Scientist will ensure during campaign that teams are communicating clearly but it helps greatly when the experiment teams are prepared and ready to work on improving communication After the launch of the rocket many teams still have work to do and must monitor their experiments Although the urge to celebrate will be strong everyone in the science center must consider possible other work and how their actions can affect possible events the unforeseen included Recovery The helicopters are equipped with direction finders for the payload beacon signal and can also be equipped with a payload TM receiver for data reception of the payload s GPS position During the flight the payload trajectory will be tracked by means of the transmitted GPS data and by use of a slant range system in the TM ground stations During the descent of the payload the prediction on the impact point co ordinates is reported to the helicopters from Esrange The helicopters start their operation to locate the payload immediately after the impact At the impact site the helicopter crew disassembles time critical samples from the payload for the quickest possible return to the Esrange laboratories The recovery crew can also interact with the experiment modules e g inserting disarm plugs if this is required it should be clearly included in the SED and again on an illustrated recovery sheet as well as d
49. is during the bench tests of the payload where you will first trial the experiment with the service system During countdown all team members and any observing personnel must keep noise levels to a reasonable level that neither distracts nor disrupts experiment team operations This includes not breaking line of sight between the project scientist and the point of communication for teams not blocking anyone s vision of the countdown clock minimizing movement within the science centre and no horse play being silly At 20 minutes the doors will be closed and people will no longer be able to enter or leave the building make sure your team is prepared for this eventuality At this point experimenters must sit down be quiet and be still Experimenters must keep a careful eye on their own experiments and consider any risks that could affect their experiments If something occurs that endangers the success of their experiments contact the Scientific Officer quickly and clearly so that the issue can be resolved If issues can be foreseen please inform the Project Scientist before but do not forget to maintain a vigilant watch over any actions that may affect your 12 8 Page 74 REXUS User Manual EuroLauncH experiment in a negative way as it may not always be possible for the Project Scientist to monitor every experiment Please see the Communication Discipline section above for pro words that can be used to ma
50. is included in the design of heat sensitive experiment modules The thermal environment in the launcher housing will be controlled before launch Normally the vehicle will be in the housing with an air temperature of 17 7 C Prior to launch the housing is removed and the launcher is elevated ready for launch This is the phase during which the rocket will see the coldest temperatures This time period is nominally 20 minutes However in the case of a hold between T 20 minutes and launch this period can be extended indefinitely Experimenters must be fully aware of how low temperature conditions can affect their experiments The Service System can provide low levels of heating during this phase but this cannot guarantee specific temperatures During other phases the thermal environment can be controlled when required 6 1 3 Flight Phase The thermal environment of the outer structure of a front end positioned parallel bay module on an Improved Orion motor flight can reach 110 C at 50 seconds after lift off Peak temperatures above 200 C for the skin are expected during the re entry phase This will of course be transferred to internal parts especially to items mounted onto the skin For more detailed temperature information please see previous flight temperature profiles 6 1 4 Post Flight Phase After the impact the payload will be subjected to snow and cold air in the impact area for a period of typically one to two hours The tem
51. is location is defined by the geodetic latitude ga and geodetic longitude 0 Page 82 REXUS User Manual E UROLAUNCH North Pole East Figure A 14 4 Local Tangent Coordinate System LTC Two observation angles define the position of the rocket from the observation location The azimuth f is measured clockwise around the observation location starting in direction North It varies between 0 and 360 and is calculated with the following equation p arcan Eae Eq A 8 north rc The Elevation e is measured between the horizon and the rocket position It varies between 90 and 90 and is calculated with the following equation hrc Eq A 9 yeast rc north The transformation between azimuth and elevation to Cartesian LTC coordinates is done with following equation arctan east rc sin J cos north d cos J cos E Eq A 10 Arre sine The distance d between the rocket and the observation location is also called slant range A 5 Vehicle Carried Vertical Frame VCVF This system moves with the rocket and the origin is the centre of gravity of the rocket The velocity and acceleration that are calculated with the GPS data are usually also given in this coordinate system The Nvcvr axis points to the local North and the Evcvr axis to the local East The Zvcvr axis builds a right hand system and is perpendicular to the local plane Only the equator it is oriented exactly to the Earth
52. is suddenly switched off 10 4 5 Mass Properties Measurement and Balancing Following the above testing the integrated payload is shipped to Kista Sweden for the mass properties and balancing where the mass properties of the payload are measured and aligned The following measurements are performed by EuroLaunch before sending the payload to Esrange e Payload Mass e Centre of gravity e Spin Tip Indicator Run Out Static and Dynamic Imbalance e Moments of inertia During the balancing the payload is subject to 3 Hz spin for several minutes Experiment teams are not required at the spin and balance 10 4 6 Bend Test A bend test is normally not performed However if such a test is necessary the payload will be attached at the payload rocket motor interface and a force will be applied perpendicular to the structure giving rise to a torque on the payload rocket motor interface The deflection will be measured at three positions along the payload body These tests are performed by EuroLaunch if needed 10 4 7 Payload Vibration Test A vibration test of the complete REXUS payload is normally not performed 11 Page 65 EuroLAuNcH REXUS User Manual LAUNCH CAMPAIGN The duration of a REXUS launch campaign is approximately 12 days in spring This does not allow any time for errors or delays so it is important to be well prepared Each morning there is a status meeting in one of the Esrange conference rooms where th
53. iscussed with the crew during the campaign If early recovery is required a second helicopter is acquired to carry the payload back to the range The whole operation is normally completed within two hours of the launch Only personnel crucial for the mission are permitted to join the recovery operation and must have permission from Operations Officer to do so 13 13 1 13 2 13 3 Page 75 EuroLauncH REXUS User Manual POST LAUNCH ACTIVITIES Post flight meeting After the recovery a Post Flight Meeting is held to debrief the flight and a short flight performance report is stated A short presentation of the performance of each experiment is requested Disassembly of the payload The day after launch disassembly and packing will start It is up to the owner of the experiment to decide about transportation of their experiment and equipment All items left at Esrange will be thrown away and destruction costs for hazardous items may be charged to the experiment teams All materials left behind should be clearly labelled to determine the best disposal method Campaign report Esrange will issue a campaign report within one month 14 14 1 14 2 14 3 Page 76 REXUS User Manual EuroLauncH EXPERIMENT QUALITY ASSURANCE The major concerns of EuroLaunch related to Quality Assurance QA on the experiment level are that the experiment shall fulfil the interface requirements and that the module can f
54. k is fully transparent the experiment teams should implement a data protocol as showed in Figure 7 1 below Figure 7 1 Downlink Protocol Example Page 45 REXUS User Manual EuroLauncH To avoid channel bandwidth overload it is recommended to add a 3 ms pause between the data blocks see Figure 7 5 Figure 7 2 Downlink Channel Timing REMARK During the recent campaigns a data loss could be monitored under certain circumstances This gap solution eliminates the effect but it is recommended that the experiment teams shall keep this part of their software flexible Maybe higher data rates are possible depending of the data frame structure This has to be checked out in advance For more important TM TC Information please see the PCM Telemetry System document 9 from DLR MORABA This is available on the Team Site in the References folder 7 6 3 Telecommand Interface A RS 422 interface supplies the appropriate commands to each experiment The formatting failure recognizing and correction are also in the responsibility of the experiment teams Baud rate 38 4 kbit s standard Format 8 bits 1 start and stop bit no parity The same parameters as on the downlink should be used Due to the fact that the uplink capacity is considerably low the gap should be minimal 200 ms wide 1f 24 byte blocks are sent 7 6 4 Power Interface The power standard 28 V DC is delivered by the RXSM The supply volta
55. le Venting Holes To avoid pressure build up within the payload and to avoid gas flow between modules it is sometimes necessary to have venting holes in experiment modules One hole of 10 mm in diameter is recommended for each 15 dm of evacuated air volume A small cap such as the one shown in Figure 5 10 shall cover the holes During re entry hot air might enter the module through the venting holes and it is recommended to protect or avoid placing heat sensitive equipment near these holes Venting hole 10mm Protective cap Figure 5 10 Venting Hole with Cap Ejectables and Free Falling Units It is possible to eject items from the modules but this requires an RFW as it is beyond the standard scope of REXUS Contact your ZARM DLR or SSC ESA supervisor for this document See section 5 10 1 regarding ejectables free falling units and effects on flight dynamics The design of any hatch and release mechanism will be closely followed by EuroLaunch External Skin Mounts It is possible to mount items on the exterior of the modules but this requires an RFW as it is beyond the standard scope of REXUS Contact your ZARM DLR or SSC ESA supervisor for this document 5 8 5 9 5 10 Page 38 REXUS User Manual E UROLAUNCH Great care must be taken with the design of externally mounted objects due to the possibility of influencing flight dynamics The size should be kept to a minimum and i
56. ly in a REXUS payload without jeopardising the performance of the other systems or experiments In addition EuroLaunch has a strong concern that the experiments shall perform nominally The following advice reflects these concerns Materials In addition to normal concerns when choosing materials special attention shall be paid to out gassing phenomena due to vacuum environment during flight As an aid the ECSS Q 70 71 6 Data for selection of space materials and processes may be used Components All electrical and mechanical components must have a reliability that is consistent with the overall reliability of the payload For electronic components MIL std specified types are recommended Additional Quality Topics In addition to the QA topics above the following topics shall be addressed if required by EuroLaunch 14 3 1 Procured Products and Audits Careful planning of the procurement and manufacturing must be made for identification of long lead items Preferably a flow chart shall be made which shows the sequence of operations 14 3 2 Manufacturing Control and Inspection For the manufacturing and inspection of critical processes the personnel should be aware of standards in applicable areas such as e Manual soldering according to ECSS Q ST 70 08C e Crimping of connections according to ECSS Q ST 70 26C Specific requirements of the project or product concerning cleanliness contamination and environment shall be
57. minal REXUS flight trajectory is dependent on payload mass and configuration as well as latest motor data Please read the pre flight version of the Flight Requirement Plan for valid flight events and nominal trajectory data The following table gives an overview of the flight events during the REXUS 10 mission The yo yo release Chapter 4 1 2 for de spin of the rocket is not part of the standard configuration Table 4 1 REXUS 10 Approximate Flight Events EVENT Time s Altitude km Range km Lift off 0 00 0 332 0 00 Burn Out 26 00 20 38 2 83 Nose Cone Ejection 61 00 52 73 8 89 Possible Yo Yo Release 65 00 55 68 9 58 Motor Separation 66 00 56 39 9 76 Apogee 140 00 82 45 22 42 Payload Impact 800 0 6 42 77 REXUS User Manual 4 3 2 Graphs of typical trajectory Graphs based on GPS data for the flight of REXUS 10 The valid nominal trajectory data of your mission will be part of the Flight Requirement Plan EuroLauncH A DLR and SSC cooperation Altitude m Trajectory Profile Altitude m Altitude 0 10 20 30 40 50 0 100 200 300 400 500 600 700 800 Ground Range KM Time s Ground Range Sla
58. munication Discipline Observe the following regarding all communication e Use functional names avoid personal names e Use basic English e Spell by analogy if necessary e Use pro words below to minimize the risk of mis readings e No horse play or bad language e Minimize all radio traffic from 5M until 1M Pro words Meaning Affirmative YES Negative NO Active Work commanded is in progress completion will be reported Break Break I must interrupt this conversation because of an urgent message Correction You have made a mistake You should have said or performed or I have made a mistake I should have said Disregard Disregard what I have just said It is not applicable or is in error Execute Carry out the instruction Go ahead I am on the net Proceed with your transmission I say again I am repeating the message for clarity Out I have completed this conversation Proceed Go ahead with your task I copy I received your last message satisfactorily and understand I copy Wilco I have received your message understand it and will comply Say again Repeat your last communication Speak slower You are talking too fast Standby I must pause for time or wait a few moments Verify Check status or correctness Roger Acknowledge your transmission 12 7 Page 73 REXUS User Manual EuroLauncH Call sign during preparation Functi
59. must be mounted before launch The figure below shows a recommended design of a hatch All hatches must follow the shape of the module Outer structure Haich Figure 5 9 Hatch Example 5 3 2 Inflight Actuated Hatches Inflight actuated hatches are beyond the standard scope of REXUS The use of any hatches requires a Request for Waiver RFW to be approved by DLR and SSC Contact your ZARM DLR or SSC ESA supervisor for this document When such hatches are allowed they must e Becurved and flush with the module skin follow the shape of the module e Have no significant influence on flight dynamics The hatch retention systems must e Beat least single failure tolerant e Fully inside the experiment module e Be verifiable for correct retention after assembly i e verifying tension of retention cables The verification process must include e A vibration test to the qualification levels with a model of the design e A long duration retention tests minimum 7 days to show that there is no significant deterioration of performance of the retention system 5 4 5 5 5 6 5 7 Page 37 REXUS User Manual E UROLAUNCH The actuation process must e Leave no material hanging out from the module e Leave no unconstrained debris or material inside the payload Exhaust Openings Reaction forces from exhaust openings shall be minimised by using at least two openings located symmetrically on the modu
60. n 3 5 Page 20 REXUS User Manual EuroLauncH T 13 5m SED v1 0 submitted T 13 m Student Training Week STW at SSC Esrange Space Center or DLR MORABA facilities Preliminary Design Review PDR T 9 m SED v2 0 submitted T 8 5 m Critical Design Review CDR at ESTEC ESA Oberpfaffenhofen DLR including soldering course T 7 5 m SED v3 0 submitted T 7m IPR at experimenters organisation T 4 5 m EAR at experimenters organisation or a ZARM SSC facility T 4m Delivery of Experiments to Integration Week ITW at ZARM Bremen experimenters required T 2 5 m Bench Test at DLR Oberpfaffenhofen experimenters required T 1m SED v4 0 submitted T 0 5m Spin and Balance Test experimenters not required T 0 m Campaign at Esrange T 0 5m Flight Report Documentation from experimenters submitted T lm Distribution of the REXUS post flight Report by EuroLaunch T 3 m SED v5 0 submitted including experiment results T 4 m Publication of Final Report Results Seminar Experimenter Documentation Requirements 3 5 1 Student Experiment Documentation SED The SED provides EuroLaunch and other stakeholders from SNSB ESA DER and ZARM with all the important information on a particular experiment During the phases of experiment development production and flight the SED will be the main documentation for students to describe their experiment and 5 frozen versions will be provided see 3 4 1 All documentation relating to the requirements
61. n of the umbilical shall be in accordance with EuroLaunch instructions 7 10 2 Electrical Umbilical Provided by Experiment Teams The module mounted connector will be mounted on a flange arrangement as shown below The connector is male and the socket at the module is female Figure 7 5 Umbilical Connection and Socket 7 10 3 High Power Connections If a high power connection is required the experiment designer is free to choose the type of connector The connector is however subject to EuroLaunch approval Furthermore EuroLaunch will decide after discussions with the experiment designer where and how the connector shall be mounted 7 10 4 Ground Support Equipment Umbilical Interface Payloads are provided with Ground Support Equipment providing charging and hard line communication See the cyan EGSE box below Page 51 REXUS User Manual NRZ amp CLK i4 1 TC SMC TC H L 422 SCIENCE NET REXUS NET ESR POSNET DATA DATA GPS EGSE storage ECSEGUI STORAGE Figure 7 7 Communication Overview The figure above shows the total data signal paths of a REXUS rocket ground segment configuration Electro Magnetic Compatibility The design shall be such that radiated Electromagnetic Interference EMI is kept as low as possible it shall not interfere with other onboard systems General guidelines of the design are as f
62. nager PM Esrange appoints a Project Manager for every project that is planned to be carried out from Esrange The Project Manager is the Esrange contact for the range user The user is responsible for coordination and delegation of responsibilities of campaign activities safety matters campaign planning co ordination countdown procedure and operations at the range 12 4 2 Payload Engineer PE The Payload Engineer handles the rocket service system and switches the experiments on and off 12 4 3 Project Scientist SCI The Project Scientist e Acts as a focal point for the experiment teams during countdown 12 5 Page 70 REXUS User Manual EuroLauncH e Relays questions between the experiment teams and the Operations Officer via WT or telephone e Informs the Operations Officer and the Payload Manager about the status of the experiments e Sends a Go or NoGo signal to the Operations Officer 12 4 4 Operations Officer OP The Operations Officer handles the countdown and is the focal point for all activities Communication take places over the com loop voice link the Go NoGo system and the PA system During the countdown phase important countdown information is displayed on PA video monitors at various locations around Esrange 12 4 5 Telemetry personnel TM Together the Esrange and DLR telemetry personnel handle the receiving transmitting and recording equipment during preparation and launch 12 4 6 Launc
63. ndbook ver 2 Esrange 2011 http www sscspace com file usershandbook pdf ECSS Space product assurance Data for selection of space materials and processes ECSS Q 70 71A rev 1 ESA Publications Division 2004 http ecss nl forums ecss dispatch cgi standards showFile 100362 4200406221232 17 No ECSS Q 70 71Arev1 2818June2004 29 pdf EuroLaunch SED Template EuroLaunch 2010 EuroLaunch SED Guidelines EuroLaunch 2010 DLR REXUS IV ff TMTC Structure Mobile Raketenbasis 2009 Tutiempo Network Historical Weather KIRUNA GEOFYSISKA Sweden TuTiempo net Tutiempo Network 2010 http www tutiempo net en Climate KIRUNA_GEOFYSISKA 02 1998 20450 htm 1 4 Page 15 REXUS User Manual EuroLauncH Applicable documents 11 Montenbruck Oliver amp Gill Eberhard Satellite Orbits Springer Verlag 2000 12 Vallado David A Fundamentals of Astrodynamics and Applications McGraw Hill Companies Inc 1997 13 Sounding Rockets Program Office NASA Sounding Rocket Program Handbook Suborbital amp Special Orbital Projects Directorate 2005 Page 16 REXUS User Manual EuroLauncH ALWAYS READ THIS There is plenty of useful information in this manual Make sure that you have found and understood the meaning of the following information Experiment safety If there are hazardous items such as chemicals free falling objects lasers radiation etc included in the experiments there may b
64. nt Range 45 90 40 80 35 70 E30 E 60 9 9 8 25 8 50 m m x a x 20 v 40 2 gt 9 15 2 30 o o 10 20 5 10 0 0 0 100 200 300 400 500 600 700 800 0 100 200 300 400 500 600 Time s Time s Ground Speed Vertical Speed 300 1500 1000 E E E 3 x500 d__ __ o o o o a a a S 04 2 5 0 X 200 400 00 600 700 800 o gt 500 0 100 200 300 400 500 elo 700 800 50 L 1000 Time s Time s Page 26 REXUS User Manual EuroLauncH A DLR and SSC cooperation Page 27 Time s Total Velocity Roll Rate 1400 7 1100 4 1200 4 900 1000 t 1700 E 800 o o9 9 3600 500 4 o iv 5 400 gt 9 2 200 100 0 0 100 2 300 400 7 800 200 P po 100 Time s Time s Yaw Rate Pitch Rate 30 40 35 20 4 30 7 25 E 10 gt do 220 3 v 0 g 15 10 S 310 5 0 20 5 30 10 Time s 65000m gt 00000 m 40000 m 35000 3000041 280000 20000m 15000 m 10000 m 5000 m Kiruna Esrange Page 28 REXUS User Manual EuroLauncH A DLR and SSC cooperation As mentioned the total apogee is strongly dependant on the payload mass as demonstrated
65. ntry phase During the rest of the flight the bit error rate is lt 105 bit If a bit error hits a frame s sync information it could lose the whole frame which means that the serial data up to 32 byte per data channel contained in this frame is lost From past experiment experience both short drops and long drops in the telemetry connection should be considered in the software Experimenters must consider that drops will occur and design their software accordingly Testing with the Service System Simulator can be conducted using simulated dropouts to verify that the experiment system can cope with potential telemetry situations For details please look at previous flights data Telecommand System The REXUS telecommand system consists of the TC master located in the RXSM and TC users distributed in the experiment part of the payload Each experiment module can be individually addressed by ground commands The telecommand receiver operates in the L band Experiment data uplink during flight is not part of the standard scope of REXUS and requires an RFW Contact your ZARM DLR or SSC ESA supervisor for this document Experiment data uplink is possible during launch through the umbilical The telecommands and their characteristics must be specified and submitted in advance to EuroLaunch The interface between the TC master and each user in the TC system is implemented using an asynchronous serial link connection The overall data rate o
66. of this document can be found at the REXUS BEXUS Team Site including the SED guidelines and SED template documents 3 5 2 Campaign Requirements Plan Flight Requirements Plan Any requests for input from EuroLaunch must be fulfilled by the student teams This document is a reference document for the many people who will be involved in the launch of experiments and care must be taken that information is correct and clear to avoid errors being made concerning the experiments These requirements will be made on an individual basis with each of the teams Page 21 EuroLauncH REXUS User Manual 3 5 3 Flight Report Documentation EuroLaunch requires a post flight report document for inclusion in the Flight Report that must be produced following each launch The experimenters must submit only one to two pages regarding performance of their experiment during the flight and preliminary results when possible This must be submitted two weeks after the launch campaign each experiment team is expected to present a preliminary performance overview whilst at the campaign following the launch Page 22 REXUS User Manual E UROLAUNCH REXUS SYSTEM REXUS Vehicle A typical REXUS vehicle consists of a one stage rocket an Improved Orion motor and the payload This rocket gives approximately three minutes of spaceflight with a payload mass of up to 95 kg including the service and recovery systems Experiment Module 2 Experiment Modul
67. ollows e All power supply cables shall be twisted e Data cables shall be twisted e Incase of EMI problems shielding of the cables shall be considered To assure reliable operation the input circuits of the experiment electronics must have filters as shown below Page 52 REXUS User Manual E UROLAUNCH Common mode filter 4 1000uH Max 100uF max ripple 28V m gt DC DC 100mVpp GND Convertor RS422 Data pe use feed thru capacitors Figure 7 8 EMI Reduction 7 12 System Grounding There is one startpoint inside the SM which connects the 28 V GND to the structure of the rocket The external power supply ground PE has no galvanic connection to the 28 V circuit Note Avoid connecting the 28 V GND to a second protective earth PE terminal on the payload side e g during bench testing REXUS User Manual Grounding connected to structure at starpoint Page 53 EuroLauncH EGSE PE not connected to line of external power Launcher Ground FE Figure 7 9 Grounding Concept 8 2 8 3 8 4 8 5 8 6 Page 54 REXUS User Manual EuroLauncH GENERAL DESIGN CONSIDERATIONS Experiment Accessibility Bear in mind that designing for accessibility will make your task easier throughout the assembly and testing phases This is
68. onal names Function in the rocket processes Operation Operations Officer Launch Officer Launch Officer on launch pad Vehicle Responsible for all rocket systems Safety Safety Officer TM Telemetry station Esrange or DLR Scientist Responsible for Scientific Payload Payload Payload Manager Science Center Operations and Communication Please note this information is subject to change depending on launch requirements and operational decisions Experiment teams will be located in the Science Center during the Flight Simulation Test Test Countdown and Hot Countdown Launch Their point of communication will be the Project Scientist SCI call sign Scientist or Science All communications from the experimenter will go through this focal point see above descriptions for more information This requires that one member from each team is the communication point for the Project Scientist It must be clear which person from each experiment fulfils this role They must be located where they can always attract the attention of the Project Scientist line of sight is a requirement but also where they can receive information non disruptively from team members operating experiment ground stations The communication between the point of contact team members and the Project Scientist will be arranged during the launch week If you have queries or would like to review practices this can be done before hand A good time to consider your arrangements
69. osecone some of this space is taken by the nosecone recovery system and care must be taken to avoid interference with this Any deviations from the baseline must be agreed with EuroLaunch Note that it is in general not possible to use the full length of the module for the experiment The experiment volume allowance begins 20 mm below the top of the module and ends 10 mm below the bottom surface This ensures that there is no mechanical interference between experiments Take care when designing experiments that connectors also do not need this space so that assembly can be performed without any problems 20 mm 10 mm Figure 5 3 Experiment Module Page 32 REXUS User Manual E UROLAUNCH The following figure shows the internal coordinate system The MRL Launcher rail is at payload position 0 RAIL Umbilical 0 E gt Pa TERN O 270 C e Roll 90 CON Uld OST Figure 5 4 REXUS PL Coordinate System positive z Axis in flight direction The next figure shows the standard layout for a 14 module Page 33 REXUS User Manual F r Mocullinge 400mm Y 412mm o sta uf RS C 2 1 Figure 5 5 14 Module geometry contact DLR MORABA for details Two modules are connected by the so called RADAX joint RADAX is an abbreviation for Radial Axial Helicoils are used in the aluminium modules Following screws are used to connect the modules
70. ound safety in the launch areas during countdown and also all work with explosives at Esrange Flight Control Officer FCO is appointed when a flight includes a flight termination system He she decides to abort a flight if the vehicle deviates from a safe trajectory We accept the content of the text above Date asse nenne Customer Mission Manager Project Manager Esrange Project Manager
71. perature during the season when REXUS is launched is normally between 0 C and 30 C Experiments with samples sensitive to low temperatures after the flight must be designed for these post flight conditions 6 2 Page 41 REXUS User Manual EuroLauncH REXUS Thermal Requirements In all phases pre flight flight and post flight the following limits shall apply 6 2 1 Heating of the Outer Structure The modules internal thermal dissipation must not heat up the outer structure more than 10 C above the ambient temperature 6 2 2 Temperature at the Feed Through Cable The modules internal thermal dissipation must not heat up the parts close to or in contact with the feed through cable to more than 70 C 6 2 3 Heat Radiation in the Module Interfaces A module s internal thermal dissipation must not heat up parts facing other modules to more than 50 C 6 2 4 Convection between Connecting Modules The heat transport by convection must be limited in such a way that the air temperature at the module interfaces does not exceed the ambient temperature by more than 10 C An insulation deck in both ends of the module could be required to comply with these requirements 7 1 7 2 7 3 Page 42 REXUS User Manual EuroLauncH ELECTRICAL DESIGN OF EXPERIMENTS System Overview As mentioned in 4 1 1 the RXSM works as a data interface between the onboard systems experiments and the ground control There
72. perience of real space projects REXUS is conducted by EuroLaunch and is a cost effective easily accessible experiment facility giving 3 minutes of spaceflight up to a height of approximately 90 km EuroLaunch is a co operative agreement between SSC and the German Aerospace Center DLR Mobile Rocket Base MORABA in the area of suborbital services for sounding rocket launches and stratospheric balloon flights REXUS is financed by the Swedish National Space Board SNSB and the German Aerospace Center DLR Figure 1 1 SSC Esrange Space Center The REXUS launch campaigns are held at the SSC Esrange Space Center near Kiruna in northern Sweden The REXUS payload is modularised to provide simple interfaces good flexibility and independence between experiment modules Up to four experiment modules with a 355 6 mm 14 inch diameter and maximum total length of 800 mm can be accommodated in one payload All payload service systems necessary for telecommunication payload control launch flight and recovery are included in the system This document describes information for a user of the REXUS system including the services offered by EuroLaunch It defines the requirements that apply to the REXUS experiment modules and gives design recommendations It also includes a description of the REXUS system the programmatic elements the pre flight tests and the campaign schedule and finally there is a chapter on quality assurance and safety
73. perties Measurement and Balancing 64 10 4 6 Bend Test onda e e tte UP E ba ie rds 64 10 4 7 Payload Vibration Test ae ea en 64 LAUNCH CAMPAIGN seele 65 11 1 Description of Esrange Space Center seen 66 Fili Salo aaa al a a 66 11 2 1 Additional Esrange Safety Board Meetings 66 11 2 2 Radio Silence eere teer leet ver tee Raina 66 12 13 14 EA ns ao 66 M3 Equipment tits 66 11 4 Assembly of Rockets and Payloads eene 67 11 4 1 Assembly of Rockets aaa een 67 11 4 2 Assembly and Checkout of Payloads esee 67 11 5 Flight Simulation Tess ES Dist ante 67 11 6 Flight Acceptance Review FAR eese ira aaa 67 11 7 Flight Readiness Review FRR sense a 67 11 8 Test Countdown ssl lid alli alal 68 COUNTDOWN AND LAUNCH couleur 69 12 1 Meather COs traits 45i rera otitis 69 12 2 Launch C OBOIHODS soane at Neil 69 I2 9 vSalety In Che Launch Area a HR ken 69 12 4 Personnel during the Launch na ana ae A A a RaT 69 124 1 Esrange Project Manager PM circolanti 69 12 42 Payload Ensmeer PE ee 222 2 ee 69 12 43 Project Scientist SELL Aare Neu 69 1244 Operations Officer OB saisi doo dalai 70 12 4 5 Telemetry personnel Dista di si n 70 12 4 6 Launch Officer Vehicle VEE slitta 70 12 47 Safety Ollicer SAE a LR 70 12 5 Countdown and Lu as RE 70 12 34 2C A ee 71 1256 Communical n Disciplina A e 12 1
74. range Safety Board Meetings If a safety issue arises during a campaign there might be a need for an extra Safety Board meeting before a launch is possible 11 2 2 Radio Silence During arming of the rocket motors it is strictly forbidden to transmit or to do any power switching of an experiment or its subsystems Planning Experiment teams are strongly advised to think through all aspects of the experiment the build up all tests the launch and the flight phase With this input they should make a detailed plan of how they will work who should do what team member Esrange staff etc and how much time is needed to do everything A checklist is the key item to success even the smallest thing such as flipping a switch should be in the list Without good build up plans and checklists there is a significant risk of failures and delays during the campaign week All of this should be documented in the SED 11 3 1 Equipment There is one soldering station located in the Cathedral assembly hall There is also basic measurement equipment and toolboxes available If you need some special tools or equipment be sure to either bring it with you or specifically state that you need it when you give input to the Flight Requirements Plan Page 67 REXUS User Manual EuroLauncH Assembly of Rockets and Payloads 11 4 1 Assembly of Rockets All assembly and preparation activities for the rockets are the responsibility of the EuroLaun
75. rfaces of the experiment will be inspected at delivery to the scientific payload integration week bench test and launch campaign In general the scientific payload integration week includes only the experiment modules whereas the bench test includes the experiment modules the service system and where required for payload operation the recovery system The tests performed are very similar but after the bench test no further corrections can be made to the experiment modules Payload Assembly and Integration Tests This chapter deals with the assembly of the payload and the tests conducted on the whole integrated payload It also defines the requirements regarding the status of the experiment modules upon delivery to the payload Assembly and Integration Tests AIT The payload integration tests are performed at EuroLaunch premises and or premises leased by EuroLaunch Nominally these tests start five weeks before the planned start of the launch campaign At the start of the payload integration tests all experiments comprising the REXUS payload must be made available to EuroLaunch During some of the tests being performed technical personnel trained to handle the experiment and ground support equipment shall accompany the experiment During the AIT the experiment must be in flight configuration If the use of dummies is required this must be agreed by EuroLaunch Figure 10 1 System Bench Test REXUS 7 at DLR MORABA Page 63
76. roject Manager If the customer has own rules that are more stringent the customer s rules shall be respected when relevant and applicable Customer Positions and Responsibilities Mission Manager Project Manager is responsible for the customer s work at Esrange and is responsible to see that all customer and customer s contractor personnel follow existing rules and instructions He she is the contact point between the customer and Esrange Project Scientist is appointed by the customer and responsible for the scientific mission Payload Engineer is appointed by the customer and responsible for the technical function of the payload SSC Esrange Positions and Responsibilities Esrange Project Manager is responsible for the campaign coordination at Esrange and is the contact point between Esrange and the customer He she shall also superintend all safety and security regulations and arrangements related to the campaign Head of Esrange Launch Team is responsible for the ground safety in the launch areas and also all work with explosives at Esrange Operations Officer OP coordinates all operational work and is the interface with the customer and Swedish and foreign authorities during countdown flight and recovery Safety Officer SO is responsible for flight safety during countdown and flight He she will also control access to the launch areas and issue access permit badges where applicable Launch Officer LO is responsible for the gr
77. ssible serves multiple functions For payload organization when experiments are light and small it gives EuroLaunch more flexibility in selecting locations for each experiment It can also result in more experiments being flown In order to do this early system design solutions must be generated so that the mechanical engineers can determine the best approaches to minimizing size and mass Effectiveness of Testing When designing your experiment please take into consideration the testing in the future This is an issue of accessibility but also of design Fast and simple methods of testing calibrating or adjusting important items will save experimenters time This will also make it simpler for testing carried out by EuroLaunch 8 7 Page 55 REXUS User Manual EuroLauncH Safety Safety is of the utmost importance to EuroLaunch Any experiment that is deemed risky to the public staff or experimenters will not be flown Take care to ensure that you perform any simulation analysis and testing that will help to convince EuroLaunch that the experiment is safe to fly If there are any items that you can identify as safety risks keep them in mind during your design as the possibility exists that the experiment will be removed from the vehicle if it poses a danger 9 1 9 2 Page 56 REXUS User Manual EuroLauncH ENVIRONMENTAL TESTS PERFORMED BY THE EXPERIMENT TEAMS Environmental tests are performed in order to ver
78. sts and determination of physical properties e Transport of modules from the integration facility to Esrange e Payload assembly and testing at the range over 5 days nominally e Provision of laboratory facilities at the range e Launch and recovery 3 3 3 4 Page 19 REXUS User Manual EuroLauncH e Data acquisition with provisions of real time quick look and replay data from the modules and the payload subsystems e g g levels e Disassembly of payload and return of experiments e Post flight report Experimenter s Role Once selected to participate in the REXUS BEXUS programme the teams become a part of the mission team Their primary responsibility is to ensure the timely delivery of their portion of the scientific payload in good order This responsibility extends to defining the investigation providing the instrumentation timely processing of data and publishing of results The experimenters must also contribute to establishing and conducting the operational programme through correspondence and fulfilment of the documentation requirements The successful operation of experiments is vital to the overall success of the REXUS BEXUS missions EuroLaunch supports the teams in order to see the good scientific returns Information and expertise is available where required for assisting decisions relating to design component materials operation and any other mission related issues Final decisions are normally lef
79. t should be designed to have a very small aerodynamic effect on the payload External skin mounts must also be designed to ensure that they do not result in parachute line entanglement Use of Fluids within Modules Use of fluids within REXUS modules is allowed but considerable care must be taken to ensure that the fluids stay within the module All experiments wishing to include fluids greater than 2 mL in their experiments must use an absorbent material at the top and bottom of the module so that the possibility of fluid being transferred to other modules is eliminated This material should have the capacity to absorb twenty times the quantity of the fluid used See section 5 10 1 regarding partially filled cavities and effects on flight dynamics Dimensioning Loads during Launch Flight and Recovery The experiments should be dimensioned to withstand the loads during a complete flight profile 5 9 1 Acceleration The typical longitudinal acceleration history for an Improved Orion rocket motor is shown in shown in chapter 4 3 with a peak acceleration of 20 g Centrifugal forces will also act on the experiments since the rocket spins at 3 4 Hz 5 9 2 Re Entry Loads The typical deceleration during re entry is below 20 g and can occur in all axis 5 9 3 Landing Velocity The landing velocity is approximately 8 m s The shock at impact depends on the nature of the ground surface Nominally the landing is fairly gentle with no damag
80. t is essential to have a build up plan and checklists for your experiment Without these there is a significant risk of failures and delays during the campaign week Safety in launch area No one is allowed to visit the motor preparation hall or the launch towers without the permission of the Operations Officer Radio Silence During arming of the rocket motors it is strictly forbidden to transmit or to do any power switching of the experiments or their subsystems Page 17 REXUS User Manual EuroLauncH Campaign Requirements Plan Flight Requirements Plan This is a document that is compiled by the EuroLaunch Project Manager based on input and requests from all experiment teams Without good information well before the campaign it might be impossible to fulfil a requirement such as the provision of gases special tools etc Our goal is to have a successful and enjoyable campaign with all teams and their experiments You are always welcome to contact us with any questions 3 1 3 2 Page 18 REXUS User Manual EuroLauncH REXUS PROJECT OVERVIEW AND MILESTONES Project Organisation The technical support in the integration and testing phase as well as the campaign management and operations is provided by EuroLaunch EuroLaunch is a joint venture of SSC and the Mobile Rocket Base MORABA of the German Aerospace Centre DLR The DLR project share concerning integration testing and student support is provided by
81. t to the experimenters but if required by safety or otherwise EuroLaunch withholds the right to enforce decisions on any issue Before flight the experimenters must successfully convince EuroLaunch through testing simulation and documentation that their experiment is fit and safe for flight The experimenters are responsible for developing and providing the scientific payloads and support equipment provided EuroLaunch can aide with many of these issues but the team is responsible for ensuring that these are organised in a timely manner They are also responsible for ensuring that the experiments conform to all required electrical and mechanical interface specifications meets safety requirements and survives the flight EuroLaunch assists in all these issues where possible but the experimenters must keep in mind that ensuring the resolution of issues is their responsibility Project Planning A detailed project plan and time schedule will be released by EuroLaunch as soon as possible after the selection workshop These will be regularly updated during the project A general progress plan for REXUS flight projects is listed below Detailed descriptions of reviews and tests are given in chapter 8 3 4 1 Indicative Timetable T 18 m Call for experiment proposals T 16 m Proposal submission deadline T 16 m Proposal shortlisting T 15 5m Selection workshop at ESTEC ESA Bonn DLR presentation of proposals T 15 m Final experiment selectio
82. tests in fact the best way to do this is before via practice without signals procedure review and if possible simulation At this stage in the campaign experimenters often find themselves stressed but it is important to remain calm Due to the length of the test countdown it is important to treat it as closely as possible to a serious launch Please see below in the countdown section for the experimenters roles in this and consider your actions during all tests 12 12 1 12 2 12 3 12 4 Page 69 REXUS User Manual EuroLauncH COUNTDOWN AND LAUNCH Weather Constraints Wind flight trajectory and visibility are important variables taken into consideration before starting a countdown There are no magic numbers and the decision to start a countdown is solely in the hands of Esrange personnel Launch Conditions Launch period Usually first two weeks in March Launch window Usually 05 00 16 00 LT Visibility Sufficient for helicopter flight Safety in the Launch Area Esrange has the overall responsibility for safety and has the Veto right in all safety issues during all activities within the Esrange base area If an Esrange customer has their own rules that are more stringent the customer s rules shall be respected when relevant and applicable No one is allowed on the launch pad during countdown without the permission of the Operations officer Personnel during the Launch 12 4 1 Esrange Project Ma
83. uired to perform a test on qualification level Basic Procedure e The experiment shall be mounted on the vibration table with a suitable fixture Critical parts shall be equipped with accelerometers in order to track the response curves e Functional tests and inspection shall be performed after each axis of vibration e Vibration in X Y and Z axis should be performed as specified in below for the Improved Orion vehicle e Before and after each load vibration test a resonance search run at low level 0 25 g 5 Hz 2000 Hz 2 octave per minute shall be performed to evaluate the significant eigenfrequencies of the test items According to the NSROC 13 specification for the Improved Orion vehicle the levels for acceptance and qualification have been adapted for the REXUS Programme as shown in the next two sections Page 58 EuroLauncH A DLR and SSC cooperation REXUS User Manual 9 3 1 Acceptance Levels Vibration Acceptance levels must be performed on all flight equipment before the experiment will be accepted for flight Sinusoidal qualification test levels for axes X Y and Z 10 o c 9 9 o9 9 lt 1 10 100 1000 10000 Frequency Hz Figure 9 1 REXUS Sinusoidal acceptance test level for all axes Table 9 1 Frequency Level Sweep Rate Remark 10 50 Hz 0 124 m s 4 87 in s 4 octave per minute 50 2000 Hz 4 0 g 4 octave per minute Random vibration acceptance test
84. y for the flight For this each appointed experiment module manager shall give a status report at the meeting In addition the experiment team leaders are requested to state the operative status of the experiments e toreview the countdown list e to inform all relevant personnel of the safety regulations applicable during the countdown phase e to inform all relevant personnel of general arrangements applicable during the countdown phase canteen hours information systems etc Test Countdown After the Flight Readiness Review the rocket and payload will be rolled out to the launcher and mounted Except for extraordinary cases time constraints coupled with confidence in experiment performance a test countdown will be performed For the experimenter the test countdown will be run in much the same way as the Flight Simulation Tests However there are two important differences Please take note and consider how they may affect your experiment no lift off signal will be given umbilical remains connected this is normally a full countdown test Think about how your experiment will respond to being given other signals without the lift off signal As this will be as close to a full countdown as is possible without launching the rocket this is perhaps the most important opportunity to determine that the full experiment operation procedure is satisfactory The countdown procedure should be finalized during the flight simulation

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