Battery module mechanical development and vibration testing for Strategic Upgrades Testing Satellite (SUTS)

Abstract

Strategic Upgrades Testing Satellite (SUTS) is a PocketQube developed by Estonian Student Satellite Foundation. One of the main modules on any satellite is the battery module. The battery module is used to store energy, and without it being operational, the whole mission is put at risk or fails completely. The goal of this Bachelor’s thesis was to develop the mechanical design of the battery module for SUTS. While numerous battery modules are commercially available for CubeSats, the PocketQubes market currently lacks dedicated battery modules, which prompted the SUTS team to develop one themselves. The main goal of the mechanical design is to make sure the battery module is operational after the rocket launch and deployment to low-Earth orbit. Before design, market research was conducted on CubeSat battery modules, and based on the information gained, a design outline was created that was used to design the battery module. A design of the battery module was done with the use of static analysis and topology optimization to remove excess weight from the module without losing structural integrity. A structural prototype was created to be tested, by measuring the resonance frequencies and performing high sine and random vibration tests to ensure the quality of the battery module's structural design. The tests were conducted in the Tartu Observatory laboratory of the University of Tartu.