Dynamics simulation of pyro actuated "Ball Lock" separation system for micro-satellites to evaluate release shock

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Micro-satellite separation systems based on 'Ball Lock' release mechanism developed by ISRO for deploying microsatellites up to 150 kg mass has been successfully used in PSLV. Three varieties of such designs have been realised and qualified. They are designated as IBL230, IBL298 and IBL358. IBL stands for ISRO Ball Lock and the number stands for the interface diameter in mm. The system functions by releasing a preloaded ball locked joint between two rings by rotating a ball retainer ring using pyro assisted thrusters. This system is characterised by good joint stiffness, lightweight construction, tuneable jettisoning velocity, debris free actuation and redundancy in initiation. The system generates low release shock. To reduce the release shock further for sensitive spacecraft applications, the shock sources needs to be identified and suitable methods for attenuation to be chosen. The difficulty in identifying the contribution of shock from various sources was due to lack of complete understanding of system dynamics. Experimental verification was attempted to understand the dynamics of the release operations. Dynamic model of this system is generated for complete understanding of the release function and to quantify the impact forces that generate the shock. A dynamics model of the IBL298 system was generated. The pyro thrusters are the source of energy for release function. It is powered by ISRO standard cartridge with squib based electrical initiation. The firing of the cartridge generates pressure inside the thruster, which moves a piston and rotates the retainer ring. The pressure time relationship used for modelling is generated from the test data from a closed bomb test and used in the simulation by applying constituent equations. The system is modelled using second order dynamical equations. This model is made to capture the multiple contact losses that are likely to occur between the thruster and the lug of the ring during the movement. Magnitudes of the forces are evaluated when the thrusters are actuated simultaneously. The analysis was also carried out for off nominal conditions like one thruster not working or working with a delay. The modelling was carried out using MATLAB and solved using the odesuits. Matching with the ground test results the model parameters were firmed up. The simulation results showed that the impact forces generated at the stopper are very high. The model was further used to study the feasibility of reducing the shock, incorporating shock attenuation systems.

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