Structural Design, Modelling and Testing of a 2U CubeSat Thermal/Visual Imaging Payload

This paper provides key insights from the test campaign of a student CubeSat payload, along with actionable recommendations for future missions. The University of Bristol, UK, is developing a volcano imaging CubeSat payload - PROVE Pathfinder. This 2U payload consists of a visual and a thermal infrared camera, and their power and control electronics. In April 2023, the team conducted an environmental testing campaign at the ESA CubeSat Support Facility in Transinne, Belgium, under ESA’s Fly Your Satellite! Testing Opportunities scheme. This test campaign aimed to structurally qualify the payload to survive a nominal worst-case launch scenario, guided by relevant space testing standards.

This paper presents the structural modelling and test design process employed for the payload. Through finite element modelling, the study calculated the anticipated structural response under a varying launch environment, thereby informing the test strategy. The results of the testing campaign are presented. Challenges in mode identification within the response dynamics are acknowledged, stemming from the proximity of frequency peaks indicating that they are excited simultaneously. In addition to this, where possible, evidence-based reasons for frequency/amplitude shifts in modes are provided.

Furthermore, the paper offers recommendations for future vibration testing campaigns of CubeSat payloads, drawing upon lessons learned from this campaign. By describing the methodology and challenges encountered, it is hoped that this study helps other student teams who are contemplating the qualification of CubeSat payloads.