Upgrading to 2U - alanbjohnston/CubeSatSim GitHub Wiki

This page has instructions for upgrading a 1U CubeSatSim to a 2U. A 2U (2 Unit) CubeSat is twice as tall as a 1U CubeSat.

Materials:

You will need these materials.

Start with the CubeSatSim with the RBF plug inserted to keep it powered off.

Unscrew the four screws that secure the Frame Top and lift the top:

Unscrew the SMA antennas and the nuts on the SMA cables:

Unplug the +Z solar panel JST connector and set the Top aside. Remove the solar panels on the +Y and -Y side and unscrew the four screws on the Frame Bottom. Unplug the +X and -X solar panels. Release the black clip on the bottom of the Pi Camera on the -X side. Remove the +X and -X Frame Sides.

Unscrew the SMA coax cables from the Main board:

Install the long SMA coax cables into the Main board:

Insert two M3 nuts in the Frame Connector part in the slots marked in red in this photo:

Place one of the Frame Side parts against it and insert one screw in each side:

This photo shows where the screw should be inserted, but if you turn it like this the nuts will fall out and need to be replaced:

To tighten the screw, you will need two small screwdrivers. One Philips to tighten the screw. Another Philips or Flathead needs to be inserted into the nut slot so that the nut doesn't turn.

Here's how it looks when the screws are tightened:

Do the same for the other side so you have two Frame Sides attached to the connector:

Place the -X Frame Side with the Pi Camera on the Connector:

Make sure the black connector side of the Pi Camera is facing up:

Insert two M3 nuts and secure with two M3 screws using two screwdrivers as before:

Place the frame assembly next to the -X side of the CubeSatSim. The Pi Camera ribbon cable should be right there:

Reattach the Pi Camera ribbon cable:

Attach the frame assembly to the CubeSatSim by inserting the two screws. Now attach the +X Frame Side using two M3 nuts and two M3 screws.

Make sure the SMA cables are feeding up the frame. Attach the +Z Solar Panel JST connector. Reattach the +X and -X Solar Panel JST connectors:

You may need to partially remove the top +X Solar Panel to plug in the JST:

Connect the Frame Top and insert the SMA coax cables and secure them with the nuts.

The 2U Frame is now complete:

You can also replace some of the Solar Panels with larger ones:

You can also add a second Battery board. You will need some extra standoffs to go through the connector part. Details TBD.

Here is a very good larger solar panel that can replace one of the small solar panels: https://www.amazon.com/dp/B0CZ48NV7Z

You can make a JST Y-cable by following these instructions. This cable allows you to plug three solar panels for a side into the Solar board.

You will need two JST extender cables https://www.adafruit.com/product/1131 and some heat shrink tubing or electrical tape to insulate the wires.

Cut the extender cables so you have two female connectors and one male connector.

Strip the insulation from the wire ends. Slide the large heat shrink tube over the male wire.

On the female wires, twist then solder the red wires together and the black wires together. Cut two pieces of the smaller heat shrink tube and slide over the wires.

Solder the red wires together and the black wires together.

Slide the small heat shrink tube over the solder joints.

Heat the heat shrink tubing so it covers the joint.

Slide the larger heat shrink tubing over the joint.

Heat the heat shrink tubing to cover the joint.

Here's how you can make a folding solar panel:

These instructions show these 150 mm x 86 mm solar panels but this works just as well with these 130 mm x 85 mm solar panels. You will need 5 solar panels for this assembly, plus one more that mounts separately.

You will need 6 JST wires and four hinges

Solder the JST cables to the + and - terminals on each of the six solar panels. On two solar panels, cover all exposed terminals on the solar panels with electrical tape as shown here:

Lay out three solar panels with four hinges as shown. With the panels facing down, the hinge pin should be facing up. The distance between panels should be 16 mm. The hinges should not be centered, but instead offset so that the pin is at the edge of the outer solar panel. One set of hinges should be at the bottom of the panel. The other set of hinges should be 120 mm higher.

Secure the hinges to the panels with hot glue or double stick tape:

Lay out the two panels with the taped terminal along side the outer solar panels, but upside down:

Flip the panel over and secure to the other panel with hot glue or double stick tape.

Here's how the assembly of 5 solar panels looks:

Cut two strips of velcro or double stick tape to secure to the frame.

Here's the assembly with two JST Y-cables ready to mount and plug into the Solar board:

Here's how the assembly looks attached to the 2U frame:

Now attach the last solar panel to the opposite side of the frame.

Here's how it looks: