Thermal characterization testing of a robust and reliable thermal knife HDRM (Hold Down and Release Mechanism) for CubeSat deployables

Thermal knife HDRMs (Hold Down and Release Mechanisms) are commonly used in CubeSats and other small satellites. However, detailed information on proven designs is difficult to find. Design of a robust and reliable mechanism can present technical challenges which may only become apparent during testing, and often only when tested in a space representative environment. A custom thermal knife HDRM was designed and built for the antenna deployment module of EIRSAT-1 to deploy four coil spring antenna elements, but the same or a similar design could be repurposed quite easily to release a wide range of CubeSat deployables. In this design resistors are used to cut dyneema lines. For robustness and reliability, the thermal response of the mechanism must be well understood. To reach the melting point of the dyneema (150C) the power dissipated in the resistors must often exceed the maximum rated value. Therefore, choosing the operating current and the burn time is a careful trade-off between ensuring that the resistor reliably cuts the dyneema line and ensuring that the resistor, solder joints, PCB and nearby components are not damaged by the high temperatures. These choices are further complicated by the requirement that the mechanism operates over a range of temperatures. A thermal vacuum test campaign was carried out to better understand and characterise the thermal behaviour of the EIRSAT-1 mechanism. For the test a model of the mechanism was built with several temperature sensors installed. Two of these sensors were installed directly on the body of the resistors using a thermally conductive epoxy. Burn tests were performed in vacuum at temperatures between -37C and +56C. The test shows many interesting results including the effect of the dyneema lines on the thermal response, the possibility of desoldering the burn resistors and a comparison between the performance at ambient and vacuum conditions. Finally, a summary is given of the key technical challenges associated with this type of mechanism along with some recommendations to help make future designs more robust and reliable.