CATSAT Structural Design

CATSAT (Cooperative Astrophysical and Technology SATellite) is based upon an inexpensive, light, stiff and easily assembled structure. This paper details the overall design philosophy, manufacturing processes, and initial test results. The design utilizes flat aluminum panels that are screwed and bonded together, resulting in a stiff structure that costs less than $3000 and requires less than 40 hours to assemble. Honeycomb panels and rivets are not used in this structure making it very easy to manufacture, service and accommodate modifications. The horizontal shelves in the structure are supported by vertical panels to transmit forces throughout the structure. By locating components over or adjacent to the vertical panels, acceleration forces are transmitted throughout the structure as compressive and shear forces. Finite element analysis of the structure was performed to verify the strength of the panels and ensure that the resonant frequencies of the structure were met specification. Vibration testing has demonstrated that the axial frequency of vibration of the structure is 230 Hz. A critical component of the CATSAT design is the cooperative effort of the three institutions involved. The overall structural design was accomplished as senior projects in the Department of Manufacturing and Mechanical Engineering Technology at Weber State University. The University of New Hampshire and Leicester University were responsible for integrating their individual components into the overall structure. The methodology and configuration control processes that resulted in a successful structural design are discussed.