Integral Model Kit

8/14/2019 Integral Model Kit

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SCALEMODELCONSTRUCTIONMANUAL



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Cardbord Cut Out

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SCALE MODEL

Construction Manual

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This is the instruction manual for the scale model of the ESA Integral spacecraft.It is a step-by-step manual and it will probably take you a good evening tocomplete it. Words in Italic are names of actual spacecraft units andinstruments. These are listed in alphabetic order in the appendix to this manual

together with an explanation of their function.But let’s get started. What is needed?

• Cardboard

• Glue

• Scissors, small andstandard

• Ruler

• Knife

• Needles

• Toothpicks

• Barbecue sticks

• Aluminium Foil

• Thread

Take the first sheet (page 1) with thesymmetrical dark golden shapes - they willbecome part of the structure of the PayloadModule (PLM). You find letters in bluecircles for reference next to each elementthat needs to be cut out.

The elements (E) make the side panels ofthe IBIS structure; (F) the front and top,while (G) becomes the back panel. It isgrey, and if you look carefully you can

count the six surfaces, the so-called panelsof the spacecraft. On page 6 you find athree-dimensional drawing of thespacecraft. Refer to the drawing from timeto time to relate the different elements ofthe spacecraft to each other.

When you have cut out the shapes of thestructure, take a ruler and a knife and

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.

Lets leave the PLM and turn to page 3 withthe structure of the SVM . First you cut outand prepare the large part, the body of the

SVM , for folding. Work very accurately,since the folding lines will determine thecorrect angles and shapes of this majorspacecraft part. Cut out the large whitecircle and pierce the red dots with needle,toothpick and barbeque-stick. On the foursmaller side panels you find grey outlines ofa rectangle with white lines inside. Cut onlyalong these white lines with small sharpscissors. Prepare the grey lines with the

knife for folding, since they become four small flaps. On page 4 the element (C)can be glued on the underside of the octagonal piece of the main body (U).

The elements (R)are the tanks thatprotrude the SVM.The tanks are alittle tricky… -therefore you finda set of redundanttanks. Cut out anoval and first of allroll the cut out over the edge of the ruler along the long axis. Then cut along thefour white lines. After applying glue to the grey triangles you fold them under the

rectangular centre part grey triangles. Thisshould form the tanks. You may trim the edgesof the tanks, as shown on the right side in thepicture above. Push the flaps of one of the sidepanels to the inside. Apply glue on the insideand mount the tank as shown. From the outsidethe tanks looks like below:

Now follow this procedure for all four tanks beforeyou assemble the main body of the SVM . Thewhite rectangular shapes on the SVM and PLM body are thermal radiators, which have a mirror-like surface. You may want to cut aluminium foilin the same size and shape and glue them on allwhite surfaces of the SVM to give the model amore authentic look.



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The four elements (S) are hold-downs for the solararrays. Cut them out and fold along the white line tohave the same texture on both sides of the hold-down.They will be mounted on the upper edge of the SVMstructure - two on each side - left and right of the Solar Array .

The main body of the SVM looks likethis:

The top shows a cardboard cut-outthat has the footprint of the PLM . Athin thread can be glued under thiscardboard to suspend the finishedmodel in the end.

The element (B) will become the innercylinder of the SVM. Cut the elementout and fold the little dark flaps to thebackside and glue them. Roll the rectangle to a cylinder that fits into the roundcut-out of the SVM. Glue the cylinder into the SVM. See the photo below, whichshows the cylinder glued on the black underside of the SVM. The cylinderprotrudes about a centimetre from the SVM , forming the Separation Ring .

To prepare the Solar Panel assembly first pierce the red circles on both sides ofthe SVM ; first with a needle, then with the toothpick and finally widen the holewith the barbeque stick. On page 5 and 6 you find the solar panel front (V) andbacksides (W). Cut out two pieces of card the size and shape of the SolarPanels. Cut slots to take the barbecue stick. Check the correct assembly: Onlyone long stick is used. It has to go through the spacecraft’s SVM body, it has tocover the distance of the short grey arms and, finally, enter the card of the SolarPanel on each side. Mark the sticks accordingly. Verify with the tips of the stick

the size of the openings in the spacecraft body and enlarge them if necessary,so that the barbecue stick will fit through it with only little resistance. Do notforce the stick, turn it instead.

The blunt end of the barbecuestick is used in the first panelassembly. Glue the black backpanels onto the card, glue thebarbecue stick into the slot andcover with the front panel like asandwich. At that stage yourfirst Solar Array sandwich

mounted with the long barbecuestick should look like in thepicture above. When the glue of

this assembly set, use the point of the stick to pierce carefully through thespacecraft body. Repeat the sandwiching procedure for the second Solar Panel .This is when you will realise that you need an extra pair of hands to hold thebody, glue the elements together and hold them in place until they harden...

Get help!



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Finally the cylinder of the SVM is coveredwith a white MLI . Find the element (Q) onpage 3 and cut it to the size that fits into thecylinder. Therefore the edges of the circleare to be cut and bent inwards. Apply plentyof glue and place the circle into the cylinder.

Back to the PLM . On sheet 3 cut out theSpectrometer (SPI) structure, that looks likea telescope tube. In order to get the correctdiameter use a stack of 20 Eurocent coins.Roll the paper around the paper around thestack of coins and glue it together. The blackflaps on one side of the tube are to be cutand folded into the inside of the telescope.

The top of the spectrometer is the mask,element (M), which can be glued slightlybelow the upper edge. The grey flaps on

the other end fold to the inside of thetube and will be used to fix the SPI tothe base of the PLM . Mount thespectrometer subassembly between onthe ground-plate of the PLM.

On page 2 in the centre you find theoutline view of the SPI from the front.Coloured and numbered boxes correspondto cut-outs on the same page. With theexception of the odd shaped box (1), all

the others are relative straightforwardrectangular boxes. Note that the grey sidesare those that have to be glued to thetelescope. The location of each box isindicated in the outline view. If in doubt,correlate also with the 3D drawing on page7 or with the photos of the finished papermodel. The regular boxes can all beassembled following the same principle.Fold the four elements so that a frame iscreated; with bottom and top to be foldedand closing the box. However, box (1) is

more complicated and cut-outs and foldingare to be done carefully. This box, a main body with left and right smaller andlower bodies, is mounted both to the ground-plate of the PLM and against thetelescope. Also the box (4) has no floor plate, but instead the two small sidesare shaped to fit the round cylinder of the spectrometer .



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The cut-outs (O) and (N) on page 2 are parts of the StarTracker (STR). From the cut-out (O) fold an unsymmetricalbox that becomes the housing for the tube. Roll therectangular cut-out (N) tightly over a barbeque stick. Gluethe roll together and mount housing and tube together in away that the seam of the tube lines up with the grey

underside of the housing. This way it will not be visible afterintegration to the PLM. There are two nearly identical STRunits, only the length of the silver-grey top varies. Whenboth are glued and hardened, put the PLM on the side andmount the STRs, as shown in the picture below.

The same construction principle applies to theOptical Monitoring Camera (OMC) to bemounted on the other side of the PLM . Housingand tube are the two first cut-outs under (K),while the third is a shade to protect the OMC’sdetector from direct sunlight. The backside ofthe baffle is to be painted black. It will becomethe inner part of the baffle assembly. Cut alongthe triangle side panels over the length of thegrey flaps. When you have prepared the folds,the piece with the black dot will become thebase. Fold the grey flaps and the triangular

sidewalls downwards.The folding between therectangular and the dotedsquare makes the 3D shapeof the shade. The black dotwill be mounted on the tubesend. The grey end of the tubevanishes this time in thehousing. Again, pay attentionto orientation of the seam ofthe tube, so it is hidden in thefinal assembly on the PLM .

There are a few remaining boxes to be build and placed. On the side of the PLMbody the long box of cut-out (L) is to be fitted between the struts. Note that theseboxes do not have a ground plate. The open design gives you a little moreflexibility to glue the box neatly into place. The grey side faces the PLM sidewall,while the flaps face the ground plate. For a more original look you might want toput aluminium foil on the white surface of the box, which act as radiators.

This improvement of your model can actually be applied to all whitish surfaceson the PLM and the SVM .





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A p p eA p p eA p p eA p p e n d i x :n d i x :n d i x :n d i x :

I n t r o d u c t i o n t o t h e I n t e g r a l S c i e n c e

Gamma-ray astronomy is more complicated then other branches of astr onomybecause at high energioes matter is transparent, and therefore source detection andimaging cannot be accomplished with standard optical-like technologies. In addition,the weakness of the source fluxes calls for instruments with large detector areas, whichtend to make them large and heavy.

Gamma-rays represent one of the most energetic forms of radiation in nature. Theycarry large quantities of energy radiated from some of the cataclysmic of all astronomicevents, including exploding stars, colliding neutron stars, particles trapped in magneticfiields, and matter being swallowed by black holes. Integral’s payload instruments –IBIS, OMC, JEM-X and SPI – study these gamma-rays through detailed imaging andhigh resolution spectroscopy, providing scientists around the world with their clearestviews yet to the most extreme environments in our universe.

from: “The Integral Payload”, G.Sarri, P.Garre, C.Schamberg & R.CarliESA Bulletin 111, August 2002

T h e G l o s s a r y T h e G l o s s a r y T h e G l o s s a r y T h e G l o s s a r y

Coolers Contrary to our experience on Earth where air or watertransports heat from one place to the other to achieve an evendistribution of temperature, conditions in space are moreextreme. Due to the lack of any medium that could convey heatin open space, temperatures depend on whether a part of thespacecraft is illuminated by the sun (and gets quite hot) or iscast in shadow (and thus condemmed to freeze). Since thespacecraft, its units and scientific instruments are limited tocertain temperature ranges they can operate in, the temperatureof the spacecraft has to be managed actively. This is done withthe help of electric heaters and coolers. Note on the model thatthe coolers are all perpendicular oriented to the Solar Arrays orcan be shadowed by the spacecraft body itself. This way theycan radiate heat generated by units or instruments of the

spacecraft most efficiently to open space.

IBIS The Imager on-Board the Integral Satellite (IBIS) provides highresolution images of celestrial objects of all classes, rangingfrom the most compact galactic systems to extra-galactic objects

JEM-X The Joint European X-Ray Monitor (JEM-X) complements theobservations of SPI and IBIS in the lower x-ray energy band.With its low angular resolution in that energy band it adds to thecomprehencive understanding of physical phenomena in thecelestrial sources observed by the other Integral instruments.



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MLI Stands for Multi Layer Isolation, a special foil that is used as athermal isulation material in which spacecrafts are wrapped toprotect them from the harsh thermal environment in space.

Hold-down Small devices, that keep deployable elements into a stowedposition during launch, until small explosive charges release thehold-downs and deploy antennas, solar arrays e.t.c.

Optical MonitoringCamera The Optical Monitoring Camera (OMC) takes images on a largeformat CCD. These images provode data for calculating thepointing of the spacecrafts observatiory instuments with anaccuracy of a few arcseconds. Thus the OMC tells the observerexactly where in the sky the spectrometer or the IBIS is pointed.

OMC See Optical Monitoring Camera

Payload Module See PLM

PLM The payload module (PLM) is the part of a spacecraft, aseparate module dedicated to host the payload. In the case ofscientific spacecrafts the PLM hosts the science instruments andexperiments.

Radiator A radiator can be understood as a passive cooler , a surface

radiates heat from the spacecraft into space.SAS See Sun Acquisition Sensor

Separation Ring The seperation ring is connecting element between a spacecraftwith the launcheror, in other words, where they sperate fromeach other. It is a very important and thus highly reliablemanufactured mechanism.

Service Module See SVM

Solar Array The task of the Solar Arrays are to convert the energie of thesun light to electric energy for operating the spacecraft. TheSolar Arrays feed the batteries with power to operate thespacecraft. With the Solar Array Drive Mechanism the Array canbe turned and oriented to catch a maximum of sunlight available

at any given orientation. However there are operation phaseswhen the spacecraft flies through the shadow of Mars (eclipse)and the Solar Arrays are not illuminated. During these periodsthe operation of the spacecraft is done on battery power.

Spectrometer The Spectrometer on Integral (SPI) performs high resolutionspectrography. The instrument observes the most energeticphenomena in the universe, such as neutron stars, black holes,supernovae and thus will resolve some fundamental problems inphysics and astronomy.

SPI See Spectrometer

Solar Array DriveMechanismn

The Solar Array Drive Mechanism is an electrical motor at thefoot of each Solar Array that can orintate the Array to catch amaximum of sunlight available at any given orientation

Star Tracker The Star Tracker operates as the primary compass of aspacecraft. It compares the image of stars in its field of view withan internal map of the sky. As a result the spacecraft navigationsystem receives information on the orientation and attitude of thespacecraft in space. For this citical function two Star Trackers,looking at different parts of the sky, are commonly used forredundancy reasons.

STR See Star Tracker



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Sun AcquisitionSensor

The Sun Acquisition Sensor (sometimes abbreviated to SunSensor) is similar to the Star Tracker a device to determine theorientation of the spacecraft. However the Sun Sensor is cruderand thus more robust. It will only find a major light source, suchas the sun, but also the reflecting light of a closeby planetarybody (Earth, Moon, Mars). Sun Sensors play an important role in

spacecraft emergency cases. If for instance for unknownreasons the normal operation pattern is interrupted and thespacecraft does not report back to ground as it routinely shoud,the spacecraft on board computer will declare an emergency.The spacecraft shuts down all but the essential systems and isput into a slow spin. During the spin the Sun Sensor is lookingfor the Sun, and as a first measure orientates the Solar Arraystowards the Sun to charge the batteries. One by one othermanouvers are called up, such the Star Tracker operation andthe Antenna being pointed towards Earth. Then the spacecraftwill transmit its status and awaits assessment and newinstructions from the Ground Control Operators at the EuropeanSpace Agency’s Operation Centre (ESOC).

SVMThe service module (SVM) is the part of a spacecraft that as amodule is dedicated to host all utilities and services required tooperate the payload in the specified orbit. Such services are thepower management, the achievement and maintenance of theorbit, the communication management, but also the thermal andmechanical integrity.

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