Critical Design Review Patrick Weber, Dorin Blodgett, Michael Stephens, Heather Choi, Kevin Brown,...

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Critical Design Review

Patrick Weber, Dorin Blodgett, Michael Stephens, Heather Choi, Kevin Brown, Ben Lampe, Anne-Marie Suriano, Eric Robinson

November 19, 2010

11/19/2010

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Mission Overview

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11/19/2010 Presenter: Eric Robinson

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Mission Overview

Scientific Mission o Primary: Collect space dust.

o Provide a perspective of what is in our upper atmosphere.

o Particle size = nano and micro level

o Donate collected aerogel tablets to UW Geology Department for further analysis

o SEM photographs of particle trails – velocity analysis

o Identify particles – material property analysis

o Secondary:o Capture optical images/video of the Earth.

o Measure thermal and seismic effects throughout the duration of the launch.o Collect data for future projects.

Presenter: Eric Robinson11/19/2010

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Mission Overview

Engineering Missiono Engineer an extendable boom to mount a dust collector.

o Use aerogel and acrylic tablets as dust collectors.o Aerogel Density = 95 kg/m3

o Acrylic Density = 1200 kg/m3

o Engineer a water shield to protect dust collector.

o Engineer modular electronic systems for:o Capturing and storing images from optical devices.

o Recording thermal and seismic data in real time throughout launch using sensors and transferring recording data via provided NASA Wallops Telemetry.


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Mission Overview

Organizational Chart

Presenter: Eric Robinson

Project ManagerShawn Carroll

Team LeaderPatrick Weber

Physics Faculty AdvisorDr. Paul Johnson

Engineering Faculty AdvisorDr. Carl Frick

Integrated Sensors (IS)Michael Stephens

Heather Choi

Electrical Power System (EPS)Michael Stephens

Ben Lampe

Telescopic Boom (TB)Patrick WeberEric RobinsonDorin Blodgett

Optical Camera (OC)Kevin BrownNick Roder

Charles Galey

11/19/2010

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Mission Overview

Theory and Conceptso Underlying Science and Theory

o Attempt to capture space particles using telescoping boom, aerogel, and acrylic discs.

o Quantification of varying flight parameters.


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Mission Overview

Theory and Conceptso Previous Experimentation

o Previous flights have included multi-sensor packages.

o Temperature, Humidity, and Pressure Sensors

o Accelerometers / Seismic Sensors

o Magnetometers

o Data Storage (SD Cards)

o Results provided a basis for improvement on future data collection and retrieval.

o SD Cards impervious to low exposure to salt water

o Payload electrical orientation


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Mission Overview

Concept of Operations

Presenter: Eric Robinson

t ≈ 0 minLaunch

Systems Power On (t = -2 min)-Collection of Sensor Data Begins

t ≈ 0.7 minEnd of Orion Burn

t ≈ 1.7 minShedding of Skin

Boom Extends via First Timed Eventt ≈ 2.8 min

Apogee

t ≈ 4.0 minBoom Retracts via Arduino Controller

Boom Power Shut Down

t ≈ 8.2 minChute Deploys

t ≈ 15 minSplash Down

Payload Power Down

11/19/2010

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Mission Overview

Expected Resultso Successfully collect space dust

o Space Dust Composition (10-6)

o Exhausted Rocket Fuel

o Meteor / Metal Fragments

o Other Miscellaneous Gases

o Detailed data throughout flight duration

o Thermal Data

o Seismic/Vibration Data

o Earth images/video


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Design Description

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Design Description

Design Changes Since PDRo Payload water shield has been removed

o Complex manufacturability

o Electrical components do not need to be salvaged

o New Telescopic Boom Control Mechanismo Steel tape reel design (akin to a tape measure)

o New high torque gear box DC motor instead of stepper motor

o Mission Objective Changeso Pressure sensors have been removed from secondary objective


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Design Description

De-Scopes and Off-Rampso De-Scopes

o No mission objectives have been removed

o All objectives are still considered feasible

o Off-Rampso We do not believe we will run into schedule/budget constraints

that would require a contingency.


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Design Description

Subsystem Overview


MCU Arm Control

Temp. Sensor

Optical Camera

PWR

Wallops Telemetr

y

Wallops

EPS

EPS/STR Interface OC/STR

Interface

TB/STRInterface

TB/EPSInterface

OC/EPSInterface

STR

TB OC

BoomAerogel

Motor

Boom

IS IS/EPSInterface

IS/STR Interface

Temperature Sensor

Accelerometers

Optical Camer

a

Optical Camera

Accel.Sensor

Control Box

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Design Description

Mechanical Design Elements


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Design Description



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Design Description



o Retracted – 11 in boom

o Extended – ~19 in boom – ~12 in reach

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Design Description

Electrical System : Componentso Arduino Controller

o 5M Digital Camera

o 16 Mbit data flash

o 100:1 Metal gear motor

o 250 G Accelerometer

11/1/2010 Presenter: Michael Stephens

o 16G 2-Axis Accelerometer

o Temperature Sensors

o Motor Driver

o Encoders

o Power Regulators

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Design Description

Electrical System : Arduinoo Atmega 328 @ 16 MHz

o 32Kb of Program Storage

o 2KB of Ram

o Digital Pins : 14o 6 PWM

o Analog Pins : 6 o 10 Bit

o 10 KHz sample time

o Provide control over payload11/1/2010 Presenter: Michael Stephens

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Design Description

Electrical System : XY Accel.o 2 axis ± 18G

o 36 / (2^10) = 0.03515625 G Resolution @ 10 bit

o 5V @ 350 µA

o 50 Hz cut off filter

o Used last year as well

o Provide acceleration in the non extreme XY axis.


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Design Description

Electrical System : Z Accel.o 1 axis ± 250 G

o 500 / (2^10) = 0.48828125 G resolution @ 10 bit

o 5V @ 1.5 mA

o 400 Hz cutoff filter

o Provide acceleration data in the extreme Z (up) axis


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Design Description

Electrical System : Motoro 100:1 gear ratio

o 140rpm @ 6V

o 6V @ 90mA

o 800mA stall current @ 6V

o 0.9375 in-lb motor torque @ 6V

o Provide winding action of tape.


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Design Description

Electrical System : Motor Drivero 3 wire interface (In1, In2, PWM)

o 1.2 A max @ 15 V


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Design Description

Electrical System : Temp. Sensoro TMP36

o -50C to 125C = 175C range

o 175 / (2^10) = 0.170898438 degree resolution @ 10 bits

o SLOW (300s for full range change)

o 5V @ .5uA


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Design Description

Electrical System : Optics

DVR 623V 5M DSC/DV module

o 5.1 megapixel

o Internal shutter trigger

o SD Data up to 4GB

o 5V @ ? mA

o Provide photos/video of flight


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Design Description

Electrical System : Flash Storageo 16 Mbit (2MB)

o 3.3V @ 7 mA

o 36 Kbytes/second write time

o SPI Interface (4 digital pins)


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Design Description

Electrical System : Storageo Used for redundant storage of acceleration data

o Maximum sensor sampling time 400 Hz

o 3 x 10 bit = 30 bits ~ 4 bytes

o (((16 000 000 / 8) / 4) / 400) / 60 = 20.8333333 minutes of recording time.


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Design Description

Electrical System : Powero 12 V regulators

o 6V regulators

o 780X series max input voltage 35 volts.


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Design Description

Electrical System : Encodero Digital light sensor

o 2 Wires (1 enable, 1 output)

o 5V @ 25 mA

o Used to sense black and white pattern on spool.o Used to detect stalls

o Used to verify extension


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Design Description

Electrical System : Telem. IF


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Design Description

Electrical System : Power IF


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Design Description

Software Design Elements

11/1/2010

o Programmed on Arduino in “C”

o Heavy use of interrupts

Presenter: Michael Stephens

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Design Description

Software Design Elements


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Prototyping/ Analysis

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11/19/2010 Presenter: Patrick Weber

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Analysis Results

o Telescopic Boomo Finite Element Analysis

o Deflections, stress, and strain

o Newtonian Laws

o Payload Frameo Finite Element Analysis

o Deflections, stress, and strain


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Analysis ResultsTelescopic Boom - Stress

Key Resultso Stress

o Peak von Mises

o 11 MPa at truss convergence point

Loading of 100G


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Analysis ResultsTelescopic Boom – Deflection

Key Resultso Deflection

o 6061 Aluminum

o 1.12E-2 mm at

o center of boom.

o 1023 Carbon Steel

o 1.099E-2 mm at

o center of boom.

Loading of 100G


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Analysis ResultsTelescopic Boom – FOS

Key Resultso Factor of Safety

o 6061 Aluminum

o Min - 24.59

o 1023 Carbon Steel

o Min – 8.59

Loading of 100G


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Analysis ResultsMaterial Decisiono Material Strength

o Results showed that both materials could handle the loadings with minimal deflection

o Material densityo Aluminum 6061

o ρ = 0.0975 lb/cu.in.

o 1023 Carbon Steel

o ρ = 0.284 lb/cu.in.

o Therefore 6061 Aluminum Alloy will be the chosen as the material for our mechanical components.


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Analysis ResultsMaterial Decisiono Aerogel Design

o Results from aerogel studies have proven that an Aerogel Density of 95 kg/m3 will be sufficient in capturing the micro-scaled particles. [1]

o [1] – Horz, Friedrich, Mark J. Cintala, Thomas H. See, and Keiko Nakamura-Messenger. "Penetration Tracks in Aerogel. Produced by Al2O3 Spheres." Meteoritics & Planetary Science.


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Prototyping Results

o Most prototyping is theoretical and conducted using SolidWorks.

o Further prototyping and testing will occur once the parts are manufactured and assembled.o Late January/Early February


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Detailed Mass Budget

o Total Mass Budget (15±0.5 lbs)o Structure (5.95 lbs)

o Boom (5.05 lbs)

o Circuit Trays (0.9 lbs)

o Camera (0.25 lb)

o Other Sensors (1 lb)

o Modular Electrical System (1 lb)

o Ballasting (~6.80 lbs)

Presenter: Patrick Weber

Mass Budget

Boom Circuit TraysCamera Other SensorsModular Electrical System Ballasting

11/19/2010

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Detailed Power Budget

Presenter: Michael Stephens11/19/2010

o Redundant Power (2,3) @ T0 launch (17%)

o Event Power (4) @ T+5 shield ejection (80%)

Source Consumption (in Amps)Arduino 0.02Encoder 0.025Camera 0.1

Temp Sensors 0.0000015XY Acc 0.000335Z Acc 0.0015

Motor Driver 0.025Total 0.1718365

Source Consumption (in Amps)Motor 0.8Total 0.8

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Wallops Interfacing: Power


Power Connector--Customer SidePin Function1 NC2 Controller redundant power @ T03 Controller redundant power @ T04 Motor power @ T+5 after shield ejection5 Common Ground6 Common Ground7 Common Ground8 Common Ground9 NC

10 NC11 NC12 Common Ground13 Common Ground14 Common Ground15 Common Ground

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Wallops Interfacing: Telemetry


Telemetry Connector--Customer SidePin Function Pin Function1 TMP1 20 NC2 TMP2 21 NC3 TMP3 22 NC4 X Accelerometers 23 NC5 Y Accelerometers 24 NC6 Z Accelerometers 25 NC7 NC 26 NC8 NC 27 NC9 NC 28 NC

10 NC 29 NC11 NC 30 NC12 NC 31 NC

13 NC 32 TX send temp data as well as status

@19200 Baud14 NC 33 TX GNG tied to common ground15 NC 34 NC16 NC 35 NC17 NC 36 NC18 NC 37 NC19

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Manufacturing Plan

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Manufacturing Plan

Mechanical Elementso Payload Frame – 6061 Aluminum Alloy

o Machined

o Bolted together

o Telescopic Boom – Precision DOM Aluminum Tubingo Boom Housing

o Tubing with Epoxied Flange

o Intermediate Arm

o Epoxied Rail

o Aerogel Arm

o CNC machined from Aluminum Barstock

o Aerogel Purchased

o Parts submitted for machining by Tuesday, November 23rd


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Manufacturing Plan

Electrical Elementso Electrical Power System

o Arduino Board

o Integrated Sensorso Purchase

o All wires will be soldered

o All wires and boards will be epoxied to acrylic mounting plates.o Acrylic will comply with no-voltage requirement.

o Parts ordered by Wednesday, December 1st.


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Manufacturing Plan

Software Elementso Software will be developed next semester starting mid-

January 2011.

o Software will be developed in modules and integrated as a whole as they become functional.

Software developed in Arduino “C” language.


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Testing Plan

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Testing Plan

System Level Testingo Full mission simulation testing using physical model.

o Vibration testing at the University as well as Wallops.

o Boom extension/retraction test using electronics and mechanical models.

o Payload drop testing

o Thermal Expansion testing


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Testing Plan

Mechanical Testingo Prove mechanical functionality on ground

o Boom testso Cyclic Extension/Retraction Tests

o Friction Tests

o Bending/Binding Tests

o Tape Reel Buckling Strength Tests

o Thermal Expansion Tests

o Water sealant testingo Pool submersion test on canister

o Drop impact test on canister sealing

o Testing will be performed as models and utilities become available.


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Testing Plan

Electrical Testingo Temperature sensor testing

o Measure sensors 24 hours a day and correlate with other temperatures measurements.

o Place sensor unit in oven until reading stabilizes. Remove sensor and place outside at night until reading stabilizes. Do this multiple times to determine time delay.

o Hot / Cold system testo Place entire system in oven, place outside. Examine for solder

disconnects.

o Accelerometer testingo Use elevators and cars to verify acceleration readings.


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Testing Plan

Software Testingo Asynchronous data capture test

o Run Sine wave into ADC. Verify consistent timing.

o Motor control testo Extend boom

o Retract boom

o Verify extension and retraction and analyze fault conditions

o Integration testingo Use sine wave generators as sensor inputs

o Run simulated mission to detect possible data anomalies / control anomalies.

o Multiple day in the life (DITL) tests on ground. o Simulate entire mission with actual sensors.


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Risks

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Risk Walk-Down

o Risk Matrix / Mitigationo STR/TB.RSK.1: Canister seals fail

at splashdown and aerogel issaturated with water.

o TB.RSK.2: Boom jams when skinsare shed. Boom fails to open andmission objectives are not met.

o IS.RSK.1: Telemetry or flash memoryfail and data to be collected for next year’s team is lost. Secondary mission objectives are not met.

o EPS.RSK.1: Should the NASA telemetry or Timed Event circuits fail, the boom may prematurely extend causing failure of the UW payload as well as possible damage to the rocket.


Consequence

EPS.RSK.1 STR/TB.RSK.1TB.RSK.2

IS.RSK.1

Possibility

11/19/2010

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User Guide Compliance

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User Guide Compliance

11/19/2010

Requirement Status/Reason (if needed)Center of gravity in 1" plane of

plate? Unsure

Max Height < 12" In compliance

Within Keep-Out In compliance

Using < 10 A/D Lines In compliance

Using/Understand Parallel Line In compliance

Using/Understand Asynchronous Line 19200 Baud

Using X GSE Line(s) Not at this time

Using X Redundant Power Lines 1

Using X Non-Redundant Power Lines 1

Using < 1 Ah 0.152Ah total (all lines)

Using <= 28 V 3.3V - 12V


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Sharing Logistics

o Who are we sharing with? – We don’t know.o University of Northern Colorado

o Re-entry Experiment Sat: Recover a reusable deployable, attempt to dynamically control the descent of the payload, and gather data during the return trip.

o The possibility of a communication system between the AstroX payload and the UNC Re-entry Experiment Sat payload is being considered.

o Plan for collaboration?o Email, phone, road-trips to Greeley and Boulder

o Communication with Max Woods on a weekly basis.

o Grant UNC access to the AstroX private website.


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Project Management Plan

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Mechanical Schedule

o Major Mechanical Milestones:o Design Freeze at CDR (Friday, November 19, 2010)

o Blueprints submitted for manufacturing on Nov. 23

o Mechanical prototype constructed mid-January, 2011

o Mechanical prototype fully tested by end of January, 2011

o Impact and submersion testing

o Aerogel testing

Presenter: Patrick Weber11/19/2010

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Electrical Schedule

o Major Electrical Milestones:o Electrical Schematics completed by CDR

o Components ordered by December 1

o Electrical assembly and testing done by Mid February

o Control function test

o Telemetry and flash memory output test

o Fully functioning payload by end of February

Presenter: Patrick Weber11/19/2010

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Monetary Budget

o Monetary Budget (~$1200)o Structure ($600)

o Boom ($300)

o Aerogel ($300)

o Camera ($100)

o Other Sensors ($110)

o Modular Electrical System ($200)

o Correcting Factor (+$20%)


Monetary Budget

Boom CameraOther Sensors Modular Electrical SystemAerogel Correcting Factor

11/19/2010

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Work Breakdown Structure


Integrated Sensors (IS)

Electrical Power System (EPS)Telescopic Boom (TB)

Optical Camera (OC)

• Design Freeze at CDR• Submit Work Request• Manufacture Boom Parts• Assemble Boom and Structure

• Design Freeze at CDR• Order Parts by End of Fall Semester• Build Circuits• Program Microcontrollers• Test Systems• Integrate with Boom

• Design Freeze at CDR• Order Parts by End of Fall Semester• Build Circuits• Program Microcontrollers• Test Systems

• Test functionality of camera• If functional:

• Integrate with Electrical Power System and Integrated Sensors

• If non-functional:• Order another camera

11/19/2010

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Conclusions

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Mission Overview

Scientific Mission o Primary: Collect space dust.

o Provide a perspective of what is in our upper atmosphere.

o Particle size = nano and micro level

o Donate collected aerogel tablets to UW Geology Department for further analysis

o SEM photographs of particle trails – velocity analysis

o Identify particles – material property analysis

o Secondary:o Capture optical images/video of the Earth.

o Measure thermal and seismic effects throughout the duration of the launch.o Collect data for future projects.


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Mission Overview

Engineering Missiono Engineer an extendable boom to mount a dust collector.

o Use aerogel and acrylic tablets as dust collectors.o Aerogel Density = 95 kg/m3

o Acrylic Density = 1200 kg/m3

o Engineer a water shield to protect dust collector.

o Engineer modular electronic systems for:o Capturing and storing images from optical devices.

o Recording thermal and seismic data in real time throughout launch using sensors and transferring recording data via provided NASA Wallops Telemetry.


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