As science instruments on CubeSats become more sensitive to the attitude of the spacecraft, better methods must be employed to provide the accuracy needed to complete the planned mission. While systems that provide the accuracy required are available commercially, these solutions are not cost-effective, do not allow the design to be tailored to a specific mission, and most importantly, do not give students hand-on experience with attitude control actuators. This thesis documents the design, modeling, and simulation of a low-cost, student-fabricated, reaction wheel system for use in 3U CubeSat satellites. The entire design process for the development of this reaction wheel is based on fundamental design principles and can be replicated for either larger or smaller spacecraft as needed. Additionally, plans for bringing this design up to a prototyping and testing phase are outlined for continued use of this design in the Cal Poly CubeSat Laboratory.

Hardware configurations, a control law, and a steering law are developed for a mixed hardware spacecraft that uses both control moment gyros and reaction wheels. Replacing one or more gyros in a spacecraft with a reaction wheel has potential for cost savings while still achieving much greater performance than using reaction wheels alone. Several simulated tests are run to compare the performance to a traditional all reaction wheel or all control moment gyro spacecraft, including analysis of failure modes and singular configurations. The mixed system performed similarly to all gyro systems, responding within 6% of the gyro system’s time for all nominal cases. It far exceeds the performance of reaction wheel systems, taking only a fourth of the time. It also handles failures better than reduced size gyro systems. As such, it can be an effective cost saving measure for certain satellite missions.

Having an in-depth knowledge on the performance characteristics of space mechanisms in flight operation, with special attention to nominal vs. anomalous performance, is vital for mission success. On many unmanned spacecraft for Earth observation missions, reaction wheel assemblies are used in combination with magnetic torquers for their attitude control. Understanding the magnitude of potential electromagnetic interactions between both types of attitude control actuators is of particular interest for large spacecraft as they are usually equipped with strong magnetic torquers. In this frame, experimental investigations have been performed on simplified test set-ups with flight representative reaction wheel assemblies operated in external homogeneous magnetic fields as well as in close vicinity of magnetic torquers which create inhomogeneous magnetic fields. The test results have been successfully correlated with computer-based simulation output obtained from models with different levels of complexity. The impact of critical parameters like the location of magnetic torquers relative to reaction wheels and their material properties such as electrical conductivity and magnetic permeability have been particularly studied. It has been found that magnetic torquers pointing orthogonal to the reaction wheel spin axis cause the highest influence on the reaction wheel's performance characteristics. The material choice for the flywheel rotor, being either ferromagnetic or paramagnetic, has a strong influence when exposing the reaction wheel assembly to external magnetic fields. In general, the increase of loss torque noticed with all reaction wheels tested has been caused by eddy current effects. In this frame, the impact of using ferromagnetic materials has been surprisingly strong. Specifically, the local distortions and guidance of the magnetic field due to ferromagnetism has a highly amplifying effect on eddy currents. However, interestingly it has also been found that the impact of material choice is much more severe when considering homogeneous magnetic fields and strong magnetic torquers while being less important with relatively small magnetic torquers. The main reasons for this finding have been compensating effects of ferromagnetic vs. highly conductive materials. / Une connaissance approfondie des caractéristiques de performance des mécanismes spatiaux en vol, et plus particulièrement des performances nominales comparées aux performances anormales, est d’importance vitale pour la réussite d’une mission. Pour les missions d’observation de la Terre, la plupart des engins spatiaux non habités sont équipés d’ensembles de roues de réaction ainsi que de magnéto-coupleurs pour le contrôle d’attitude et la stabilisation. Comprendre l'ampleur des interactions électromagnétiques potentielles entre les deux types de capteurs de contrôle d'attitude est particulièrement pertinent pour les engins spatiaux de grande taille car ceux-ci sont généralement équipés de puissants magnéto-coupleurs. Dans ce cadre, des études expérimentales ont été réalisées sur des bancs d'essais simplifiés avec des ensembles de roues à réaction représentatifs du vol fonctionnant dans des champs magnétiques externes homogènes ainsi qu'à proximité immédiate de coupleurs magnétiques (champs magnétiques hétérogènes). Les résultats des tests ont été corrélés avec succès grâce à des simulations informatiques sur des modèles présentant différents niveaux de complexité. L'influence de paramètres critiques comme l'emplacement des magnéto-coupleurs par rapport aux roues de réaction et leurs propriétés matérielles telles que la conductivité électrique et la perméabilité relative ont été particulièrement étudiés. Il a été établi que les couples magnétiques pointant orthogonalement à l'axe de rotation de la roue de réaction ont le plus d'influence sur les caractéristiques de performance des roues de réaction. Le choix du matériau pour le rotor de volant, c’est à dire ferromagnétique ou paramagnétique, a une forte influence si l'ensemble de roue de réaction est exposé à des champs magnétiques externes. En général, l'augmentation de la perte de transfert de couple constatée avec toutes les roues de réaction testées a été causée par les effets de courants de Foucault.Dans ce cadre, l'influence des matériaux ferromagnétiques a été étonnamment forte. En effet, les distorsions qui en résultent et le guidage du champ magnétique amplifient fortement les courants de Foucault. Cependant, il a été constaté que l'effet du choix du matériau est beaucoup plus important si l'on considère des champs magnétiques homogènes et des grands coupleurs magnétiques. Toutefois, cet effet est moins important avec des petits coupleurs magnétiques.

Esta dissertação tem como objetivo o projeto de um mancal magnético para rodas de reação com aplicação na malha de controle de atitude de satélites. Mancais magnéticos são alternativas aos mancais tradicionais tais como os de esferas ou de lubrificação seco pois trabalham sem contato mecânico entre o rotor e o estator, minimizando assim a fricção entre ambas as partes. Além da minimização do atrito, o ganho em confiabilidade e vida útil da roda de reação é considerável por não apresentar desgastes mecânicos. Devido às consequências de qualquer fricção no movimento relativo entre a inércia (parte rotativa da roda de reação) e o satélite, o mancal torna-se um componente crítico da roda de reação. A fricção se traduz não apenas num maior consumo de potência elétrica, como também na introdução de uma zona morta de atuação em torque, bem como na limitação da vida útil da roda de reação devido ao gradual desgaste do mancal. O mancal proposto possui dois graus de liberdade axiais ativamente controlados e faz uso de ímãs para a estabilização passiva dos demais graus de liberdade. Ao longo do desenvolvimento são apresentados modelos não lineares dos campos magnéticos e das forças atuantes no mancal são encontrados. Com esses modelos, uma otimização é realizada a fim de encontrar melhores características. Um modelo não linear da dinâmica do rotor é desenvolvido e um controle PID capaz de estabilizar o rotor em seu ponto de equilíbrio é apresentado com o objetivo de demonstrar a viabilidade da topologia proposta. / The main objective of this work is to project a magnetic bearing for reaction wheels with application in satellite attitude control. Magnetic bearings are alternatives to traditional bearings such as ball or dry lubrication because they work without mechanical contact between the rotor and the stator thereby minimizing friction between both parts. In addition to minimizing friction, the gain in reliability and lifetime of the reaction wheel is considerable as a consequence of the absence of wear. Because of the consequences of any friction in the relative movement between the inertia (of the reaction wheel) and the satellite ( which is rigidly connected to the satellite body), the bearing becomes a critical component of the reaction wheel. The friction gives rise not only to a greater consumption of electric power, as well as the introduction of a torque dead zone operation, in a reduced lifetime of the reaction wheel due to gradual wear of the bearing. The proposed bearing has two axial degrees of freedom actively controlled and makes use of magnets for the passive stabilization of other degrees of freedom. Nonlinear models of magnetic fields and forces acting on the bearing are presented. With these models, an optimization is performed to find the best bearing characteristics. A nonlinear model rotor dynamics is developed and a PID control capable of stabilizing the active degrees of freedom presented.

The goal of this thesis is to use the Cal Poly Spacecraft Attitude Dynamics Simulator to provide proof of concept of two adaptive control theories developed by former Cal Poly students: Nonlinear Direct Model Reference Adaptive Control and Adaptive Output Feedback Control. The Spacecraft Attitude Dynamics Simulator is a student-built air bearing spacecraft simulator controlled by four reaction wheels in a pyramidal arrangement. Tests were performed to determine the effectiveness of the two adaptive control theories under nominal operating conditions, a “plug-and-play” spacecraft scenario, and under simulated actuator damage. Proof of concept of the adaptive control theories applied to attitude control of a spacecraft is provided. The adaptive control theories are shown to attain similar or improved performance over a Full State Feedback controller. However, the measurement capabilities of the simulator need to be improved before strong comparisons between the adaptive controllers and Full State Feedback can be achieved.

The analysis, verification and emulation of attitude control hardware for nanosatellite spacecraft is described. The overall focus is on hardware that pertains to a multitude of missions currently under development at the University of Toronto Institute for Aerospace Studies - Space Flight Laboratory. The requirements for these missions push the boundaries of what is currently the accepted performance level of attitude control hardware. These new performance envelopes demand new acceptance test methods which must verify the performance of the attitude control hardware. In particular, reaction wheel and hysteresis rod actuators are the focus. Results of acceptance testing are further employed in post spacecraft integration for hardware emulation. This provides for a reduced mission cost as a function of reduced spare hardware. The overall approach provides a method of acceptance testing to new performance envelopes with the benefit of cost reduction with hardware emulation for simulations during post integration.

The analysis, verification and emulation of attitude control hardware for nanosatellite spacecraft is described. The overall focus is on hardware that pertains to a multitude of missions currently under development at the University of Toronto Institute for Aerospace Studies - Space Flight Laboratory. The requirements for these missions push the boundaries of what is currently the accepted performance level of attitude control hardware. These new performance envelopes demand new acceptance test methods which must verify the performance of the attitude control hardware. In particular, reaction wheel and hysteresis rod actuators are the focus. Results of acceptance testing are further employed in post spacecraft integration for hardware emulation. This provides for a reduced mission cost as a function of reduced spare hardware. The overall approach provides a method of acceptance testing to new performance envelopes with the benefit of cost reduction with hardware emulation for simulations during post integration.

Thesis (MScEng (Electrical and Electronic Engineering))--University of Stellenbosch, 2011. / ENGLISH ABSTRACT: CubeSats are small, lightweight satellites which are often used by academic institutions due to their application potential and low cost. Because of their size and weight, less powerful attitude controllers, such as solar sails, can be used. In 2010, the Japanese satellite, Ikaros, was launched to illustrate the usage of solar sails as a propulsion system. Similarly, by exploiting the solar radiation pressure, it is possible to use a solar sail, together with three magnetorquers, to achieve 3-axis attitude control of a 3-unit CubeSat. Simulations are required to demonstrate the attitude control of a sun-synchronous, low Earth orbit CubeSat using a solar sail. To allow the adjustment of the solar sail, and its resulting torque, a mechanical structure is required which can be used to position the sail within two orthogonal axes. Although the magnetorquers and solar sail are sufficient to achieve 3-axis attitude control, the addition of a reaction wheel can be implemented in an attempt to improve this control. / AFRIKAANSE OPSOMMING: CubeSats is klein, ligte satelliete wat dikwels deur universiteite gebruik word weens hul lae koste en groot toepassings potensiaal. As gevolg van hulle gewig en grootte, kan minder kragtige posisie beheerders, soos byvoorbeeld sonseile, gebruik word. Die Japannese satelliet, Ikaros, was in 2010 gelanseer om die gebruik van ’n sonseil as aandrywingstelsel te illustreer. Net so is dit moontlik om die bestraling van die son te gebruik, met behulp van ’n sonseil, en drie magneetstange om 3-as posisiebeheer op ’n 3-eenheid CubeSat te bekom. Simulasies word benodig om die posisie beheer van ’n sonsinkrone, lae-aard wentelbaan CubeSat met ’n sonseil te demonstreer. ’n Meganiese struktuur word benodig vir die posisionering van die sonseil in twee ortogonale asse sodat die sonseil, en dus die geassosieerde draaimoment, verskuif kan word. Alhoewel die magneetstange en sonseil voldoende is om 3-as posisiebeheer te bekom, kan ’n reaksiewiel bygevoeg word om hierdie beheer te probeer verbeter.

Esta dissertação tem como objetivo o projeto de um mancal magnético para rodas de reação com aplicação na malha de controle de atitude de satélites. Mancais magnéticos são alternativas aos mancais tradicionais tais como os de esferas ou de lubrificação seco pois trabalham sem contato mecânico entre o rotor e o estator, minimizando assim a fricção entre ambas as partes. Além da minimização do atrito, o ganho em confiabilidade e vida útil da roda de reação é considerável por não apresentar desgastes mecânicos. Devido às consequências de qualquer fricção no movimento relativo entre a inércia (parte rotativa da roda de reação) e o satélite, o mancal torna-se um componente crítico da roda de reação. A fricção se traduz não apenas num maior consumo de potência elétrica, como também na introdução de uma zona morta de atuação em torque, bem como na limitação da vida útil da roda de reação devido ao gradual desgaste do mancal. O mancal proposto possui dois graus de liberdade axiais ativamente controlados e faz uso de ímãs para a estabilização passiva dos demais graus de liberdade. Ao longo do desenvolvimento são apresentados modelos não lineares dos campos magnéticos e das forças atuantes no mancal são encontrados. Com esses modelos, uma otimização é realizada a fim de encontrar melhores características. Um modelo não linear da dinâmica do rotor é desenvolvido e um controle PID capaz de estabilizar o rotor em seu ponto de equilíbrio é apresentado com o objetivo de demonstrar a viabilidade da topologia proposta. / The main objective of this work is to project a magnetic bearing for reaction wheels with application in satellite attitude control. Magnetic bearings are alternatives to traditional bearings such as ball or dry lubrication because they work without mechanical contact between the rotor and the stator thereby minimizing friction between both parts. In addition to minimizing friction, the gain in reliability and lifetime of the reaction wheel is considerable as a consequence of the absence of wear. Because of the consequences of any friction in the relative movement between the inertia (of the reaction wheel) and the satellite ( which is rigidly connected to the satellite body), the bearing becomes a critical component of the reaction wheel. The friction gives rise not only to a greater consumption of electric power, as well as the introduction of a torque dead zone operation, in a reduced lifetime of the reaction wheel due to gradual wear of the bearing. The proposed bearing has two axial degrees of freedom actively controlled and makes use of magnets for the passive stabilization of other degrees of freedom. Nonlinear models of magnetic fields and forces acting on the bearing are presented. With these models, an optimization is performed to find the best bearing characteristics. A nonlinear model rotor dynamics is developed and a PID control capable of stabilizing the active degrees of freedom presented.

In this thesis, the design of a self balancing prototype bike with a reaction wheel as balancing mechanism will be investigated. Bikes are inherently unstable systems, that dynamically resemble an inverted pendulum at a stand still. Previous work has mostly been focused on keeping the balance through manipulating the steering input, and using state space modelling in order to balance the bike. In this project, a PID controller was implemented as a mean of control for the reaction wheel which was driven by a brushless DC motor. Different variations of Ziegler Nichols tuning methods were compared, and an alternative heuristic tuning method for the PID controller was also tested. The standard Ziegler Nichols and the alternative method yielded the best results. / I detta kandidatexamensarbete kommer designen av en självbalanserande prototyp cykel med ett reaktionshjul som balanseringsmekanism att undersökas. Cyklar är instabila system, som dynamiskt liknar en inverterad pendel när de är stationära. Tidigare arbeten har huvudsakligen fokuserat på att hålla balansen genom att elektroniskt manipulera styrinmatningen och använda modern regelteknik för att balansera cykeln. I det här projektet implementerades en PID-regulator som ett medel för att styra reaktionshjulet, driven av en borstlös likströmsmotor. Olika varianter av Ziegler Nichols-metoden och den alternativa metoden gav de bästa resultaten.