THE KOREASAT5 PROGRAM - Design, AI&T, Launch and Operation KT CORPORTION
Contents I. Introduction II. Design III. Assembly, Integration and Test (AI&T) IV. Launch V. Operation VI. Q & A
THE KOREASAT 5 PROGRAM I. Introduction
KOREASAT PROGRAMS KOREASAT PROGRAM Main Satellite Characteristics
Koreasat 5 Spacecraft Launch Weight: 4.5 ton Length (tip-to-tip): 38 m Height : ~ 5 m Fig1. On Orbit Deployed Configuration
a) Koreasat 5 in AIT MCI* room b) During launch site test *MCI : Mass, Center of gravity, Inertia Fig 2. Koreasat 5 Layout
Koreasat 5 Program Summary 2T009037 Fig 3. Koreasat 5 manufacturing and launch preparation
THE KOREASAT 5 PROGRAM II. Design
Spacecraft Bus vs. Payload Bus: A means transporting goods, men, etc. - Also called platform Payload: Something that generates revenue * Example - A spacecraft is the payload for a launch vehicle Spacecraft Bus: the housekeeping subsystems - Thermal control, attitude and orbit control, electric power generation, telemetry/tracking and control, structure, propulsion subsystem. Spacecraft Payload: antenna and transponder subsystem
System Performance Budgets Power Budget Mass Budget Propellant Budget Antenna Pointing Budget Link Budget Mass and Power is the most important design factors in the whole space business
CDR : Critical Design Review EOL : End Of Life EOL Power Budget - CDR phase COMPONENTS PWR BUS NB ON MARGIN SS EQUINOX ECLIPSE Repeater + STD 100V included 5533.0 5533.0 5533.0 Antenna heaters 100 V 10.0 10.0 10.0 Repeater heaters 100 V 0.0 157.0 277.0 TOTAL PAYLOAD including Heaters 5543.0 5700.0 5820.0 TC/TM/ SM SUBSYSTEM 83.4 83.4 83.4 AOCS SUBSYSTEM 179.6 179.6 179.6 THERMAL SUBSYSTEM included 363 401 215 ANGEL SUBSYSTEM 100V 209.8 212.1 210.5 POWER SUBSYSTEM 319.1 796.4 422.5 TOTAL PLATFORM 1154.7 1672.1 1111.4 S/C REQUIREMENT (W) 6697.7 7372.1 6931.4 SOLAR ARRAY POWER (W) after 15,25 years (without failure) 8009.0 8917.0 POWER MARGIN (W) 1311.3 1544.9 POWER MARGIN (%) (Minimum required 7,5% in every phase) 19.6% 21.0% SOLAR ARRAY POWER (W) after 15,25 years with 1 string failed/ wing 7840.0 8729.0 POWER MARGIN (W) 1142.3 1356.9 POWER MARGIN (%) (Design goal 7,5% in every phase) 17.1% 18.4% AVAILABLE BATTERY ENERGY (Wh) without failure 14024.3 % OF BATTERY ENERGY USED IN ECLIPSE without failure 57.7% AVAILABLE BATTERY ENERGY (Wh) with 2 cell failed per battery 12550.0 % OF BATTERY ENERGY USED IN ECLIPSE with 2 cell failed per battery 64.4%
Mass Budget CDR phase 1798.4 9 31 39 20 45.2 2.3 1845.9 STATUS SUBSYSTEM Total mass E C Q W Uncert. Disp. Max. mass (kg) (%) (%) (%) (%) (kg) (kg) (kg) Ku-band Repeater 175.90 2 35 47 16 3.37 0.17 179.44 SHF / Ka Repeater 146.93 2 58 40 0 4.62 0.17 151.72 Ku band Antennas 32.08 2 98 0 0 1.64 0.00 33.72 Earth antennas Module 85.73 11 89 0 4.75 90.48 SHF Area horn 1.34 100 0.07 1.41 PAYLOAD 441.98 4 58 32 6 14.44 0.24 456.67 E : Estimated C : Calculation Q : Qualified W : Weighted STRUCTURE 349.57 4 51 11 35 10.14 0.47 360.19 Thermal Control 141.45 15 17 14 54 3.38 0.17 145.00 STD 25.70 100 2.57 28.27 Solar Array 201.80 8 3 88 0 1.99 0.73 204.52 EPS 207.40 35 65 0 3.61 1.53 212.54 Harness 55.68 61 4 34 3.42 0.07 59.17 Ku-band TCR 14.40 72 28 0 0.52 0.03 14.95 Command Control 67.16 5 5 91 0.48 0.75 68.38 AOCS 46.79 100 0.31 47.10 PROPULSION 175.66 3 30 66 0.55 1.09 177.31 BAPTA 12.41 100 0.18 12.59 Dep. Ant. Mechanisms 22.34 6 36 36 22 0.53 0.11 22.99 PLATFORM 1320.36 9 23 42 26 27.20 2.24 1349.80 mechanical integration 26.50 100 2.65 29.15 RF Integration 2.50 100 0.25 2.75 Electrical Integration 7.02 100 0.70 7.72 INTEGRATION 36.02 100 3.60 39.62
Propellant Budget CDR phase Koreasat 5 / Sea Launch Two Burn 01/10/2004 Service lifetime 24.34 yr Total launch payload mass Apogee altitude Perigee altitude Inclination 4465.4 kg 35786 km 2925 km 0.00 deg Launch Target Orbit Maneuvers Delta-V Specific Efficiency Weight Resulting impulse change weight (m/sec) (sec) (kg) (kg) LV payload mass 4465.4 Adaptor mass 0.00 4465.4 Transfer orbit att. 8.80 4456.6 PVA's 0.00 318.6 0.9700 0.00 4456.6 AMF1 560.49 318.6 0.9820 744.10 3712.5 AMF2 560.49 318.6 0.9820 619.86 3092.6 AMF3 100.00 317.4 0.9890 98.85 2993.8 PMF1 0.00 317.4 0.9950 0.00 2993.8 Post-apogee maneuver 5.00 288.2 0.9000 5.88 2987.9 Station repositioning 11.36 288.2 0.9000 13.31 2974.6 Attitude: 1st half life 9.74 2964.9 N/S 1136.62 285.3 0.9200 1058.39 1906.5 E/W 53.56 285.0 0.9000 40.16 1866.3 Attitude: 2nd half life 9.74 1856.6 Station repositioning 5.68 285.0 0.9000 4.19 1852.4 Transfer Orbit Fuel Use : ~ 1,500 kg On-Orbit Fuel Use : ~ 1,100 kg On-orbit raising 5.47 284.2 0.9000 4.03 1848.4 Dispersion corrections 32.97 285.0 1.0000 21.67 1826.7 Propellant residual 21.28 1805.4 Total propellant req. 2660.00 Excess tank capacity 0.00 Pressurant (Helium) 7.00 1798.4 Dry spacecraft 1798.4
Design/Verifications Design Constraints 1. Bus Design Constraints 2. System Performance Requirements 3. Environmental Requirements 4. Operational Requirements Test Verification Component Test System/Subsystem/Module Tests
Design Constraints 1. Bus Design Constraints a) Various communications payload selections Ku-band channels + Ka-band channels, or Several combinations of C, S, Ku, Ka-band applications b) Requires modifications on the basic bus design to accommodate the Customer-specified payload requirements
Design Constraints c) The payload design should consider the well established bus design for cost-effectiveness. Given Heat Pipe Panel Design Given heat pipe network design: constraints on the TWTA mounting locations Given Antenna Feed Location Feed horn locations on the earth deck are pre-defined: Stable points, minimum loss, etc. Given OMUX Mounting Location OMUX s are relatively big in size and should be placed to minimize the RF loss up to the antenna.
Design Constraints 2. System Performance Requirements Link Budget Must meet the allocated link margin within the real estate given by the system engineering (e.g., waveguide and cable length, heat pipe network pattern). Antenna Pointing Error Budget RF performance depends on the antenna pointing errors. System engineering allocates the errors that must be flown down to the RF design requirements. Thermal Dissipation Budget The payload design should comply with the panel s heat transport capability. Conductive vs. radiation-cooled TWTA, deployable radiators
Design Constraints Mass Budget All subsystem designs should be compliant with the mass allocations given by system engineering 5 ~ 10% mass margin added up to the baseline design figures at the beginning of the design Power Budget All subsystem power consumption should be compliant with the power allocations given by system engineering 5 ~ 10% power margin added up to the baseline design figures at the beginning of the design
Design Constraints 3. Environmental Requirements Space Environments Thermal: thermal cycling, components operational temp. are sensitive to the RF performance Vacuum: vacuum sensitive units, active units Corona Arcing: high power handling units ESD (Electrostatic Discharge): active units Ground Environments Cleanness Handling requirements: Easy installation and removal, transportation
Design Constraints 4. Operational Requirements Customer-specific requirements TWTA operational range Output Back-off range from Saturation TDMA operation: No. of TDMA operation channels BUS voltage ripples & EMI/EMC protection Beam Interconnectivity OMUX design & layout
THE KOREASAT 5 PROGRAM III. Assembly, Integration & Test (AI&T)
Typical System AI&T Components Module System System module final assembly System and core module assembly Ambient functional (SPT1) Vibration/ acoustic test (SPT2) Thermal vacuum test (SPT3) System module System module test Core module Core module tests Solar array module Solar array module test Spacecraft shipping container Spacecraft shipping configuration Range test (SPT4) Reflectors Antenna module test Battery modules Battery module test K-T216
Component Acceptance Test Flow Initial or reference performance test Pressure and leak tests (if applicable) Random vibration or acoustic tests Post vibration test Thermal vacuum or thermal cycle test Pressure and leak tests (if applicable) EMI/EMC (if applicable) Final performance test To module integration and test
Koreasat 5 System AI&T SM/CM Mating East/West Panel INTEGRATED SYSTEM TEST 1A Body Alignment / Electrical Performance Test / Propulsion etc. (Initial Performance Test) Antenna Mounting Align/Dismounting SPACECRAFT TV Pre-TV / Thermal Balance / Thermal Cycling Antenna Mounting & Alignment ASSY ASSY ASSY INTEGRATED SYSTEM TEST 1B Vib. test adaptor Battery MECHANICAL ENVIROMENTAL TEST 1 Ant. Manual Deployment ASSY S/A Manual Deployment ASSY Tank Filling (Simul. Liquids) Sine Vibration Acoustic Test Solar Array (S/A) INTEGRATED SYSTEM TEST 2B INTEGRATED SYSTEM TEST 2A Ant. Pyro Deployment S/A Pyro Deployment ASSY Body Alignment / Electrical Perf. Test / Propulsion etc. (Final Performance Test) Solar Array CATR / EMC TEST MECHANICAL TEST 2 Satellite Preparation for Flight CATR Compact Ant. Test Range EMC Launch EMC RE/RS Tank Filling Adaptor Fit Check Separation Shock Test Ant. / S/A Mounting Global Leak Check Shipment Preparation
Fig 4. To enter the test facility room after the launch site arrival
THE KOREASAT 5 PROGRAM IV. Launch
Launch Vehicle Selection Launch Capability - Launch site - Maximum launch capability Spacecraft Interface Compatibility - Fairing Size, Mech.&Elect. Interface, etc Launch Slots - 6 ~ 10 launches per year Laws and Regulations - Government approval needed for contract execution
Koreasat 5 Launch Fig. 5 Sea Launch Site (Home Port, Long Beach )
a) Fairing Encapsulation b) Transfer to Launch Platform (LP) c) Move to Launch Platform Hangar Fig 6. Combined Operation and Launch Vehicle Loading to LP
Koreasat 5 Launch Site EQUATOR
Koreasat 5 Launch Fig. 7 Lift-Off Moment
Launch and Early Orbit Operation (LEOP) AMF : Apogee Motor Firing SAM : Sun Acquisition Mode ORM : Orbit Raising Mode IAAM : Inertia Attitude Acquisition Mode
LEOP Ground Network (Panamsat Network) FUC : Fucino Station, Italy HBK : Hartebeestoek Station, South Africa GNA : Gnangara Station, Australia CRK : Castle Rock Station, USA
THE KOREASAT 5 PROGRAM V. Operation
Purpose of Satellite Control To maintain the required orbital location and attitude Koreasat 5 Location Location : 113 E Orbital Box : ±0.05
Purpose of Satellite Control To provide the sufficient electrical power and the benign operating conditions during the satellite mission life
SCC : Satellite Control Center IF/BB : Intermediate Frequency / BaseBand M & C : Monitor & Control LMA : Limited Motion Antenna FMA : Full Motion Antenna KT Ground Station
KT Satellite Services DBS : Direct Broadcasting Satellite CATV : Cable TV Transmission TVRO : TV Receive Only VSAT : Very Small Aperture Terminal SMDS : Satellite Mobile Data Service SNG : Satellite News Gathering MTS DBS SNG SNG Transponder Lease CATV TVRO VSAT SMDS
THE KOREASAT 5 PROGRAM VI. Q/A
Thank You