QUBIK Assembly Guide¶

Please read through this guide before proceeding

Glove box preparation¶

Check anti-static mat is connected to ground
Check anti-static bracelets are connected to ground
Check glove box is clean from dust, if not use vacuum to clean it
Wear anti-static bracelets during the whole process
Wear gloves during the whole process
Wear properly the sleeves of glove box
In all process the glove box must be remained clean

Tools¶

Clean and insert all needed tools in the glove box:

metal self-locking tweezers
metal curved tweezers
torque-wrench with 5mm socket(needed for M2 and M2.5 PH screws and nuts)
scissors
M2.5 nut tightener bit for 5mm socket
5mm hex key
thrash can
PH-1 screw driver
PH-1 bit for 5mm socket
cutting pliers (flush)
Epoxy Resin Adhesive Dispenser
Poke needle for applying epoxy glue

Consumables¶

Clean and insert all needed consumables in the glove box:

Dyneema string, 0.14mm diameter
Loctite 9466 - Epoxy glue
Epoxy mixing nozzle tip (for epoxy dispenser)
Blue threadlocker glue
Cyanoacrylate glue

Parts¶

Assume that all the parts are ready to fly (tested, glued and conformal coating, cleaned).

RBF pin
Assembly stand
Assembled Base plate
Top Frame
4x [FrameScrews], long screws
4x battery stand-offs, long stand-offs
Assembled BMPS, included battery pack
12x short stand-offs
Assembled ballast board
Assembled PQ9ish COMMS
Bottom Frame
COMMS Programmer cable
Main harness
Antenna cable
4x [BasePlateNuts] nuts
4x Assembled Side solar panels
Assembled Top solar panel
4x [TopSolarScrews]

Assembly Steps¶

Base Plate¶

Base Plate to Assembly stand

Insert cleaned Base Plate into the “Assembly stand” with thermal knifes first
Lock it with the RBF pin

Harness connection

Connect QBP2CH harness to connector J2
Insert QBP2BMPSH harness to connector J1
Insert U.Fl Antenna cable to J6

Secure cables with Epoxy

Prepare epoxy glue
Apply a small amount of glue on all connected connectors on the base plate

Top frame¶

Top Frame

Take one “top frame” and four M2.5x60 DIN965 screws
insert M2.5x60 DIN965 screws from the countersink side of holes
Place kapton tape on screw heads as to not fall when frame is handled

Place the frame with the bolt heads facing down
Insert four long stand-offs onto each bolt and set assembly aside

BMPS¶

Connect battery

Connect Battery to BMPS connector J2

Attach BMPS

Orient BMPS so PQ9 connector is on the same side as the frame antenna notch of “top frame”
Take assembled BMPS and place it on the stack.

Important: Make sure that the harness is on the outside of the frame screw and spacer

Mass Ballast¶

Attach Mass Ballast

Add four short stand-offs

Add assembled ballast board to the stack, align PQ9ISH connector (top/bottom left/right based on connector)

COMMS¶

Attach COMMS

Add four short stand-offs

Add COMMS board and align with PQ9ish connector
Add four short stand-offs

Bottom frame¶

Attach bottom frame

Place “bottom frame” onto the stack
Hand-Tighten the M2.5 screws leaving about 5mm at the tip of the screw from bottom frame

Note: The small gap under the bottom frame will ease solar panel installation

Attachment to base Plate¶

Attach structure to base plate

Align the structure with base plate
The PQ9ish connector should on the same side with the thermal knifes (Y-)

Pass QBP2BMPSH 6 pin connector between bottom frame and COMMS on X+ Side
Pass QBP2BMPSH 4 pin connector between bottom frame and COMMS on Y+ Side
Pass QBP2CH between bottom frame and COMMS on Y+ Side

Connect the antenna connector to COMMS

Note: the antenna connector can be connected later but it will be more difficult to position

Place the structure on the base plate taking care that the screws go through the respective screw holes in the base plate
Place a rubber band over the entire structure and assembly Frame

Attention Make sure that cables are not pinched between bottom frame and base plate

Flip over the entire structure and place it with the top frame resting on the table

Place the 4 [BasePlateNuts] nuts on the screws
Hand tighten the nuts until the bottom frame does not move

Attention Make sure that cables are not pinched between bottom frame and base plate

Flip the structure over with the assembly base laying flat on the table
Remove rubber band

Note: There will be a free play on the top frame and subsystems. This is normal in order to assist in side panel placement

Harness connection¶

Preparation:

In the following steps epoxy glue will need to be applied.

Read carefully the procedure before preparing epoxy glue.

Connect harnesses

Connect QBP2CH harness to COMMS 6-pin connector
Apply epoxy glue

Connect QBP2BMPSH to BMPS J1
Apply epoxy glue

Attention At this point, removing the satellite from the assembly base will activate the satellite

Apply epoxy glue to COMMS antenna cable

Tip: Use a small plastic rod to apply glue

Note: Allow epoxy to dry before continuing to the next steps

Side solar panels¶

Preface: Side solar panels are secured all at once by the top and bottom frames. This will require some coordination for the correct alignment

Side solar panels have an inductor protruding on the inner side. This inductor is positioned in such a way that will slide between 2 subsystems

All side solar panels are interchangeable

Attach side solar panels

Position side solar panels
If needed gently lift the subsystems in order to align the solar panel inductor
Add a rubber band to keep all side solar panels in place
Align top and bottom tabs of the solar panels with the top and bottom frame slots
Gently push the top frame towards the base plate until all solar panels are secure

Place a rubber band over the entire structure and assembly base in order for the side solar panels to remain in place
Carefully screw the M2.5x60 DIN965 screws
Remove all rubber bands

Tightening torques
M2.5x60 DIN965	0.6 Nm

Flip over the entire structure and place it with the top frame resting on the table
Screw the 4 M2.5 DIN934 nuts

Tightening torques
Apply Loctite 9466
M2.5 DIN934	0.6 Nm

Top solar panel¶

Attach top solar panels

Connect harness QBP2BMPSH to connector J1 on Top Solar Panel
Apply epoxy glue on J1 connector
Ensure that the six Top Solar Panel contact pads are covered with Kapton tape

Align the top solar panel notches with the antenna (Y axis). Harness connector should be on the harness side (Y+)
Secure top solar panel using 4 M2x6, DIN7985 screws

Tightening torques
Apply Loctite 9466
M2x6, DIN7985	0.4 Nm

Antenna Stowing¶

Antenna tie down

Pass the Dyneema string under the thermal knife.
Start from from outer side (Y-) towards inner side (Y+).

Pass the string through the antenna string loop

Pass the string under the second thermal knife from inner side (Y+) towards outer side (Y-)

Finally pass it again through the antenna string mount

Cut the Dyneema string allowing for at least 10cm extra length

Make a square knot

Note: A square knot is adequate to loosely keep the antenna from unfolding while it can be tightened a later step

Fold the open end of the antenna under the string loop end.

Make sure that the Dyneema string is at located at the center of each thermal knife
While holding the open end of the antenna in place, tighten the square knot
The antenna should push against the antenna release detector.
Verify proper position by ensuring that there is continuity on the test points using an DMM.

Verify that the Dyneema string is at the center of each thermal knife
Verify that the antenna is fully folded
Verify the continuity of the antenna release detector
Make 5 additional square knots

Add a drop of CA glue on the knots to secure them in place