DOCUMENT NAME System Engineering Report

DOCUMENT NO. 01

DATE MODIFIED 21st Oct 2024

PREPARED BY

APPROVED BY M. Talha Imran

 Dept. Electrical Engineering
Course SE - 608440
Date 21-Oct-2024
Project: ICUBE-1
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LIST OF MODIFICATIONS

Section/ Pages
Date Issue Modified by Reason for change
Affected

Review and
2022-12-24 1.0 All
formatting
 Dept. Electrical Engineering
Course SE - 608440
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Project: ICUBE-1
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LIST OF ABBREVIATIONS

ADCS Attitude Determination and Control Systems

OBC On Board Computer

EPS Electrical Power Subsystem

PCB Printed Circuit Board

 Dept. Electrical Engineering
Course SE - 608440
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Project: ICUBE-1
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LIST OF TABLES
Table 1: Communication Protocol Comparison..........................................................................................14
Table 2: Telemetry Protocol Comparison Table..........................................................................................20
Table 3: Inter-Opcodes (External)...............................................................................................................21
Table 4: Intra-Opcodes (internal).................................................................................................................21
Table 5: Pin Assignment..............................................................................................................................26
 Dept. Electrical Engineering
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LIST OF FIGURES
Figure 1: Operational Modes of ICUBE-1.....................................................................................................7
Figure 2: Power Consumption ICUBE-1........................................................................................................7
 Dept. Electrical Engineering
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Date 21-Oct-2024
Project: ICUBE-1
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TABLE OF CONTENTS
LIST OF MODIFICATIONS......................................................................................................................I
LIST OF ABBREVIATIONS....................................................................................................................II
LIST OF TABLES....................................................................................................................................III
LIST OF FIGURES...................................................................................................................................IV
1. SCOPE..................................................................................................................................................7
2. OBJECTIVE........................................................................................................................................7
3. LITERATURE REVIEW...................................................................................................................7
4. BLOCK DIAGRAM..........................................................................................................................23
5. HARDWARE RESOURCE..............................................................................................................23
6. MISSION REQUIREMENT.............................................................................................................23
REFERENCES...........................................................................................................................................25
 Dept. Electrical Engineering
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Project: ICUBE-1
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TABLE OF CONTENTS
1. SCOPE
The scope of this project is to detail the ICUBE-1 development by focusing on the functional subsystems,
mission requirements, and system engineering analysis. The report covers structural, power, communication,
payload, and thermal systems alongside the procedures for integration, testing, and deployment.
2. OBJECTIVE
The goal of the ICUBE-1 project is to develop and launch Pakistan’s first student satellite, enabling
hands-on learning in satellite development. The primary objective is to establish a functioning satellite
with telemetry, tracking, and control capabilities. A secondary goal is capturing Earth images using a
low-resolution CMOS camera.

3. LITERATURE REVIEW
3.1 Introduction to CubeSat:
CubeSats are miniaturized satellites following a standardized 10 cm³ (1U) form factor. These satellites are
designed to promote cost-effective space missions, making them an ideal platform for educational
institutions and research organizations. Since the launch of the CubeSat program in 1999 by Stanford
University and California Polytechnic State University (CalPoly), more than 60 institutions have
contributed to its evolution.
CubeSats typically serve a variety of purposes, such as technology demonstrations, Earth observations,
communications experiments, and student learning programs. Their use of Commercial Off-The-Shelf
(COTS) components simplifies the design process, accelerates deployment, and reduces costs.

Figure 1: Dimensions of CubeSat

 Dept. Electrical Engineering
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3.1.1 ICUBE-1 by Institute of Space Technology, SSTR Lab

ICUBE-1 is Pakistan's first student-built satellite, developed under the Institute of Space Technology
(IST) in Islamabad. The project was initiated to provide students with hands-on experience in satellite
design and to demonstrate Pakistan's capacity to develop and launch CubeSats. This satellite follows
the 1U CubeSat standard and is aimed at performing experimental tasks, such as establishing
communication with a ground station and taking low-resolution Earth images.
The primary goals of ICUBE-1 include:

 Technical Learning: Train students in all phases of satellite development, from design to
operations.
 Communication Link: Establish telemetry, tracking, and command (TT&C) capabilities.
 Payload Operations: Capture images using a CMOS camera and transfer data back to Earth.

Figure 2: ICUBE-1

3.2 Introduction to iCube-1 Structure:

The structural design of ICUBE-1 follows the 1U CubeSat standard (10 cm × 10 cm × 10 cm) to ensure
compatibility with the Poly-Picosatellite Orbital Deployer (P-POD). The structure is critical for
providing mechanical support during the satellite’s deployment, maintaining component alignment, and
withstanding the harsh environmental and vibrational forces encountered during launch and in-orbit
operation.

Materials and Design Considerations

1. Materials Used:
o Aluminum 5052-H32: Used for the main structure due to its high strength, corrosion
resistance, and ease of machining.
o Aluminum 6061-T6: Utilized for components requiring additional mechanical strength,
such as the rails in contact with the P-POD launcher.
o Surface Treatment:
 Anodizing: Applied to rail surfaces to prevent cold welding inside the P-POD
launcher.
 Alodining: Used on other surfaces to act as a Faraday cage, shielding the
satellite’s electronics from external electromagnetic interference.
2. Structure Provider:
o ICUBE-1's structure was supplied by Pumpkin Inc., a company known for providing
space-proven CubeSat kits. These kits meet the CubeSat Design Specifications, ensuring
seamless deployment from the P-POD launcher.
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3.2.1 Structure of iCube-1

The structural design of ICUBE-1 is crucial for ensuring the integrity and functionality of the satellite while
adhering to CubeSat specifications. Here’s a detailed overview of its structure, materials used, and design
features:
Structural Specifications
1. Dimensions:

o ICUBE-1 is designed as a 1U CubeSat, which means it has a standard size of 10 cm x 10 cm x

10 cm and a maximum mass of 1.33 kg. This compact size facilitates efficient deployment and
integration with launch vehicles.

2. Material:

o The primary material used for the structure is Aluminium 5052-H32, known for its excellent
strength-to-weight ratio and resistance to corrosion. This choice of material ensures durability in
the harsh environment of space.

o The feet of the CubeSat are machined from Aluminium 6061-T6, providing additional strength
and support during deployment.

3. Design Features:

o The structure incorporates hard anodized surfaces on the four rail surfaces that contact the
Poly-Picosatellite Orbital Deployer (P-POD) to allow smooth deployment and prevent cold
welding.

o The remaining surfaces are treated with alodine, providing a protective layer that also serves as
a Faraday cage, shielding ICUBE-1 from external electric fields.

4. Deployment Mechanism:

o The design includes a Remove Before Flight (RBF) pin, ensuring the satellite remains inactive
during transportation and launch.

o It also features a deployment switch and two separation springs, which are critical for the safe
deployment of the satellite from the P-POD once it reaches orbit.

3.2.2 Dimensions and Shape of ICUBE-1

The dimensions and shape of ICUBE-1 play a crucial role in its design and functionality as a CubeSat. Here’s a
detailed commentary on these aspects:
 Dept. Electrical Engineering
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Project: ICUBE-1
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Dimensions
1. Standard Size:

o ICUBE-1 is designed as a 1U CubeSat, with dimensions of 10 cm x 10 cm x 10 cm. This

standardized size is essential for compatibility with launch vehicles and deployment systems like
the Poly-Picosatellite Orbital Deployer (P-POD).

o The compact size allows for efficient use of space, which is critical in satellite design where
every cubic centimeter counts.

2. Mass Limitations:

o The maximum mass for a 1U CubeSat is 1.33 kg. ICUBE-1 adheres to this limit, ensuring that it
can be launched as a secondary payload without exceeding weight restrictions imposed by the
launch vehicle.

3. Scalability:

o While ICUBE-1 is a 1U configuration, the CubeSat standard allows for variations, such as 2U
and 3U designs, where one dimension can be increased while maintaining the other two as fixed.
This scalability provides flexibility in design for future missions or more complex payloads.

3.2.3 Shape
1. Cube Geometry:

o The cubic shape of ICUBE-1 is not only aesthetically pleasing but also functionally
advantageous. The uniform shape allows for even distribution of structural loads, which is
important during launch and in the space environment.

o A cube is inherently stable, providing a solid foundation for mounting various subsystems, solar
panels, and antennas.

2. Solar Panel Integration:

o The design utilizes five faces of the cube for solar panel placement, maximizing the surface area
available for power generation while preserving the compact form factor. This is critical for
maintaining power supply in space.

3. Aerodynamic Considerations:

o While the CubeSat shape is not primarily designed for aerodynamics (as it operates in a
vacuum), the cubic structure does facilitate straightforward deployment from the P-POD,
ensuring that the satellite can be released efficiently into orbit.

4. Interfacing with Other Systems:

o The standardized cubic shape allows ICUBE-1 to be easily integrated with various launch
systems and platforms, ensuring compatibility with international CubeSat launch initiatives.
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3.3 Operation modes:
ICUBE-1 is designed to operate in five distinct modes, each serving a specific purpose to optimize power
usage, ensure functionality, and maintain communication with ground stations. These modes are:
1. Emergency Mode

o Purpose: This mode is activated in response to critical anomalies, such as Single Event
Upsets (SEUs) or Single Event Latch-ups (SELs) that could compromise the satellite's
functionality.

o Functionality:

 All non-essential subsystems are powered down immediately to conserve energy and
prevent further damage.

 The On-Board Computer (OBC) is rebooted using a watchdog timer, which helps
recover from errors by resetting the system.

o Importance: This mode is crucial for maintaining satellite integrity and ensuring that the
satellite can recover from unexpected faults.

2. Power Saving Mode

o Purpose: Engaged when the battery charge drops below a predefined threshold to prolong
operational life during low power situations.

o Functionality:

 All subsystems are powered off, except the OBC, which remains active to monitor
system status and respond to ground commands.

 This mode helps to prevent total battery depletion, allowing the satellite to resume
normal operations once adequate power is available.

o Importance: By conserving energy, ICUBE-1 can survive longer periods without sunlight,
particularly during eclipses.

3. Normal Mode

o Purpose: This mode represents the standard operational state of ICUBE-1, where routine
tasks are performed.

o Functionality:

 The satellite carries out housekeeping tasks, such as monitoring subsystem health and
environmental conditions.

 It transmits a beacon signal at predetermined intervals to indicate its operational status

to ground stations.

o Importance: Normal mode is essential for maintaining ongoing satellite operations and
ensuring that the system functions within expected parameters.
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4. Payload Mode

o Purpose: Dedicated to tasks associated with the satellite’s primary mission of Earth
observation.

o Functionality:

 The satellite performs image acquisition, utilizing the onboard CMOS camera to
capture data.

 Images are then compressed to reduce data size using a separate microcontroller
before being stored in the onboard memory for later transmission.

 This mode also includes routine data collection for monitoring the payload’s
performance.

o Importance: Payload mode is critical for fulfilling the scientific objectives of ICUBE-1,
allowing it to gather and process imagery for research and analysis.

5. Transmit Mode

o Purpose: Activated during contact with ground stations to facilitate communication.

o Functionality:

 ICUBE-1 transmits telemetry data, including health status and payload information, to
the ground.

 It receives commands from ground operators, allowing for real-time adjustments to

operations based on current conditions or requirements.

 The communication system uses specified amateur frequency bands, ensuring

compliance with regulations and facilitating interaction with multiple ground stations.

o Importance: Transmit mode is vital for maintaining a reliable link between the satellite and
ground control, enabling operators to monitor the satellite’s performance and issue commands
as needed.
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Figure 3: Operational Modes

3.4 Communication System of ICUBE-1:

Uplink (VHF with AFSK Modulation):
 Frequency Band: VHF (Very High Frequency), typically ranging from 30 MHz to 300 MHz This
frequency is widely used for satellite communications due to its long-range capabilities and reduced
atmospheric attenuation.

 Modulation: AFSK (Audio Frequency Shift Keying) is used for uplink communication. AFSK
modulates the audio tones to encode digital data, making it a simple method for transferring binary
information using sound. It involves shifting the frequency between two audio tones (typically 1200
Hz and 2200 Hz) to represent binary '0' and '1'.

 Data Rate: The uplink data rate is 1200 bps (bits per second). This relatively low data rate is
sufficient for sending command signals to the satellite, as command messages are usually short.

 Purpose: The ground station sends commands to the satellite in this uplink channel to control satellite
operations, switch modes, request data, or adjust settings.

Downlink (UHF with BPSK Modulation):

 Frequency Band: UHF (Ultra High Frequency), ranging from 300 MHz to 3 GHz. UHF is suitable
for satellite telemetry and payload transmission due to its ability to penetrate atmospheric layers and
handle higher data rates.

 Modulation: BPSK (Binary Phase Shift Keying) is used for downlink communication. In BPSK, the
phase of the carrier signal is shifted to represent binary data ('0' and '1'). It is a robust modulation
scheme, especially useful in noisy communication environments like space, ensuring reliable data
transmission over long distances.
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 Data Rate: The downlink also operates at 1200 bps, transferring telemetry and payload data (e.g.,
images from the onboard camera) to the ground station.

 Purpose: The satellite sends telemetry (health and status data), payload data (images and sensor data),
and housekeeping information to the ground station.

CW Beacon (Continuous Wave):

 Function: The CW beacon transmits telemetry data using Morse code. This provides a simple and
low-power method for continuously sending basic health data, such as battery status, temperature, and
system operation updates.

 Purpose: The beacon allows amateur radio operators and ground stations to monitor the satellite’s
status even if more complex data transmissions are not occurring. It is used to verify that the satellite
is operational and can be identified easily.

AX.25 Protocol:
 Function: AX.25 is a packet-based communication protocol that was originally designed for
amateur radio operators. It is an extension of the X.25 protocol (used in early packet-switched
networks) and is highly suitable for error-checked, reliable transmission of data over noisy
communication channels, like those encountered in space.

 Features: AX.25 supports error detection, ensuring that transmitted packets are intact and correctly
received. If errors are detected, packets can be retransmitted. The protocol also includes addressing
information, so packets can be routed between different stations.

 Application: ICUBE-1 uses AX.25 for both telemetry and payload data transmission, ensuring that
ground stations receive reliable, error-free data from the satellite. Packetized data transmission is
particularly useful in space communications, where signal disruptions or losses may occur.

Summary:
 The uplink uses VHF and AFSK modulation at 1200 bps to receive commands.

 The downlink uses UHF and BPSK modulation at 1200 bps to send telemetry and payload data.

 The CW beacon continuously transmits basic health information in Morse code.

 The satellite uses the AX.25 protocol to ensure reliable, error-checked transmission of data between
the satellite and ground stations, making the system robust in the challenging space environment.

This communication setup allows ICUBE-1 to maintain a reliable link with the ground station for efficient
control and data collection during its mission

3.5 Power Consumption and Specification of iCube-1:

Power management is critical for the successful operation of ICUBE-1, particularly given its small size and
reliance on solar energy. Here’s a detailed overview of the power specifications, consumption requirements,
and management strategies employed in ICUBE-1.
Power Specifications
1. Power Generation:
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o Solar Cells: ICUBE-1 uses Advanced Triple Junction (ATJ) solar cells, which are highly
efficient, capable of achieving efficiencies greater than 27.5% at 25°C.

o Configuration: The satellite features solar panels on five faces, with each panel consisting of
two solar cells, delivering approximately 2W per panel.

o Total Solar Power Generation: Under optimal conditions, the maximum power generated
can reach approximately 4.68W when the satellite is perfectly oriented towards the sun.

2. Battery System:

o Type: ICUBE-1 is equipped with two rechargeable lithium-ion polymer batteries connected in
series.

o Capacity: Each battery has a capacity of 1500 mAh at 3.7V, providing a total energy storage
capacity sufficient to support operations during eclipses.

o Charging: The batteries are charged/discharged at a rate of C/2, allowing for approximately
5W of continuous power for two hours when fully charged.

3. Power Board:

o The power board from Clyde-Space is responsible for managing the distribution of power to
various subsystems, featuring high efficiency (over 90%) and protections against overcurrent
and undervoltage.

Power Consumption Requirements

1. Subsystems Power Consumption:

o Each subsystem of ICUBE-1 has specific power requirements that need to be managed
effectively. Here’s a breakdown of expected consumption for key subsystems:

 On-Board Computer (OBC): Primarily consumes around 2 mA, which is negligible

compared to other subsystems.

 Communication System: The transceiver operates with a power output of

approximately 300 mW during transmission.

 Payload (Imaging Module): The CMOS camera, when active, requires additional
power; however, specific consumption figures may vary based on operational
conditions.

 Power Management and Sensors: Additional power will be consumed by sensors

and telemetry systems, which need to be accounted for during operational planning.

2. Operational Modes and Consumption:

o Different operational modes of ICUBE-1 impact overall power consumption:

 Normal Mode: Active housekeeping tasks and beacon signal transmission will draw
power continuously.
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 Payload Mode: Engaging the imaging module and processing images will result in
higher power usage, necessitating careful monitoring of battery levels.

 Transmit Mode: Power consumption peaks during communication with ground

stations, requiring adequate battery reserves to ensure successful data transmission.

3.6 Communication Payload of iCube-1:

ICUBE-1 carried a communication system capable of transmitting and receiving signals to and from
ground stations. This system allowed the CubeSat to send telemetry data, including satellite status, to
ground control and receive commands from Earth.

Camera:

The CubeSat included a low-resolution camera as part of its payload, aimed at capturing images from
space, providing Earth imagery, and demonstrating imaging technology in orbit.

Pakistan’s first CubeSat ICUBE-1. Like a number of new CubeSats its communications subsystem is
capable of acting as an “AO-16 mode” FM to DSB transponder.The IARU amateur satellite frequency
coordination panel pages say that the VHF downlink will operate as a 1k2 BPSK beacon but has the
capability of being configured as an FM-DSB transponder. A downlink on 145.947 MHz and an
uplink on 435.060 MHz have been coordinated.

It is planned to have an imaging payload with a small low resolution CMOS sensor. The C3188A
imaging module uses Omnivision’s CMOS image sensor OV7620. The camera will be mounted on the
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Z+ face of the ICUBE and can take continental scale images.

The payload of iCUBE-1 consisted of a communication system for telemetry, command handling, and
amateur radio operation, alongside a low-resolution camera for experimental Earth imaging. These
components, designed within the constraints of a small CubeSat platform, helped fulfill the satellite’s
mission of technological demonstration, education, and experimentation.

CMOS Imaging Sensor

The CMOS imaging sensor is the primary payload of the ICUBE-1 satellite.. In this case, the C3188A
CMOS camera module, with an Omnivision OV7620 sensor, is responsible for capturing images of the
Earth, which is one of the key secondary objectives of the ICUBE-1 mission.The camera captures low-
resolution images that are then stored onboard and later transmitted to the ground station, making it the
satellite's primary payload.
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Here is a table summarizing the specifications of the payload for the ICUBE-1 satellite:

Specification Details
Payload Type CMOS Imaging Module (C3188A)
Sensor Type Omnivision OV7620 CMOS Color Sensor
Resolution 664 x 492 pixels
Pixel Size 7.6 µm
Lens 1/3” lens, 6 mm focal length
Ground Resolution 824 m x 824 m (at 650 km altitude)
Raw Image Size 980,064 bits (approx. 980 KB)
Compressed Image Size 392,025 bits (approx. 49 KB at 90% quality)
(JPEG)
Image Capture Limitations Can capture images of one hemisphere due to passive
attitude control system
Data Storage Images stored in onboard memory (SD card)
Data Transmission 4-5 compressed images per day (depending on bandwidth)
Communication Window Approx. 54 minutes per day with ground station

3.7 Internal Communication Protocols and their comparison

ICUBE-1 employs the MSP430F1612 microcontroller from Texas Instruments as its On-Board Computer
(OBC). This choice is significant due to the microcontroller's features that align well with the requirements of
small satellite operations.
Specifications of the MSP430F1612
1. Architecture:

o 16-bit RISC architecture, which allows for efficient processing with lower power
consumption compared to 32-bit alternatives.

2. Power Consumption:

o Extremely low power consumption, with a maximum current draw of only 2 mA. This
characteristic is crucial for a satellite operating in environments where power resources are
limited, particularly when relying on solar panels.

3. Memory:

o Flash Memory: 55 KB, which provides ample space for storing firmware and operational
code.

o RAM: 5 KB, sufficient for handling data and temporary processing tasks during operations.

4. Analog Interfaces:

o Equipped with a 12-bit Analog-to-Digital Converter (ADC) and Digital-to-Analog Converter

(DAC), allowing for precise measurement and control of analog signals from various
subsystems.

5. Communication Interfaces:
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o Multiple communication options including I2C, SPI, and USART, enabling versatile data
exchange between the OBC and other satellite subsystems.

o I2C is primarily used for inter-subsystem communication, which is critical for coordinating
tasks and gathering data from different sensors.

6. Operating Voltage:

o Operates at a voltage range of 1.8V to 3.6V, making it compatible with the satellite's power
systems.

7. Environmental Tolerance:

o The MSP430 series is known for its robustness, making it suitable for the harsh conditions of
space, including radiation exposure.

Reasons for Choosing the MSP430F1612

1. Low Power Requirements:

o The primary advantage of the MSP430F1612 is its low power consumption, essential for
maximizing the operational life of ICUBE-1, especially during periods of limited solar
exposure.

2. Adequate Processing Power:

o The 16-bit architecture strikes a balance between processing capability and energy efficiency,
allowing ICUBE-1 to perform necessary computations without excessive power draw.

3. Sufficient Memory:

o The onboard memory is adequate for the tasks required by ICUBE-1, including handling
telemetry data, commands, and data from the imaging payload.

4. Versatile Communication Interfaces:

o The availability of multiple communication protocols enables seamless integration with

various subsystems, facilitating effective data management and command execution.

5. Proven Reliability:

o The MSP430 series has a history of use in various aerospace applications, providing
confidence in its performance and reliability in space missions.

6. Support for Sensor Integration:

o Its ADC capabilities allow ICUBE-1 to interface with various sensors, essential for
monitoring the satellite's health and environmental conditions.

3.8 Budget of the iCube-1:

The ICUBE-1 project was an important milestone for Pakistan’s space research, designed and launched by the
Institute of Space Technology (IST). The total budget for the satellite was PKR 14.5 million, divided between
satellite development and launch costs. Below is a detailed analysis of how the budget was allocated and its
 Dept. Electrical Engineering
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implications:

1. Breakdown of the Project Budget

Satellite Development Costs: PKR 3.5 million
 This budget covered the design, assembly, and testing of the ICUBE-1 satellite.
 The team used commercial off-the-shelf (COTS) components to keep costs low while
ensuring that the satellite met international CubeSat standards.
 Structural components were purchased from Pumpkin Inc., USA, a supplier of space-
grade CubeSat kits.
Launch Costs: PKR 11 million
 This budget was allocated for integration with the launch vehicle and deployment in Low
Earth Orbit (LEO).
 The satellite was launched aboard a Dnepr rocket from Russia, an economical launch
solution frequently used by small satellite programs worldwide.

2. Comparison with Typical Satellite Budgets

Traditional satellite projects often cost between $5 to $10 million USD (approximately PKR 1.4 to
2.8 billion) due to higher component, integration, and testing expenses.
In contrast, IST’s ICUBE-1 project demonstrates frugal innovation by completing the mission with
just PKR 14.5 million. This cost-effective approach allows for reduced financial risks and quicker
execution timelines.

3. Key Strategies for Cost Optimization

Use of COTS Components:
 Relying on readily available components reduced procurement costs and shortened
development timelines.
 However, this comes with trade-offs, such as limited customization and exposure to
radiation risks in space.
International Launch Collaboration:
 Partnering with Russian launch services provided a low-cost opportunity to deploy
ICUBE-1. This is a common strategy for university satellite programs worldwide, as
dedicated satellite launches are prohibitively expensive.
In-House Expertise and Facilities:
 IST’s reliance on student and faculty efforts minimized labor costs. The ground station at
IST was also developed in-house, further reducing operational expenses.
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4 BLOCK DIAGRAM
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REFERENCES
https://www.ist.edu.pk/news-2013-icube-1-launch

https://www.ist.edu.pk/icube-1#

https://nssdc.gsfc.nasa.gov/nmc/spacecraft/display.action?id=2013-066S

https://www.nanosats.eu/sat/icube-1

https://www.researchgate.net/publication/259531002_ICUBE-
1_First_Step_towards_Developing_an_Experimental_Pico-
satellite_at_Institute_of_Space_Technology/link/
00b7d52c6685fa6adc000000/download?
_tp=eyJjb250ZXh0Ijp7ImZpcnN0UGFnZSI6InB1YmxpY2F0aW9uIiwic
GFnZSI6InB1YmxpY2F0aW9uIn19