2013 CDR

Space Crusaders Critical Design Review

Northwest Nazarene University Benjamin Gordon, Seth Leija, Drew Johnson, David Vinson,

Jameson Krueger, Lukas Rieke, Aaron Ewing, Patrick Richardson, Dakota Martin, Darrell Leber, Alex Hanson,

Ryan Lofthouse, Jon Hamilton

December 11th, 2012

2013 CDR

CDR Presentation Outline

•  Section 1: Mission Overview •  Section 2: Design Description •  Section 3: Subsystem Design •  Section 4: Prototyping/Analysis •  Section 5: Manufacturing Plan •  Section 6: Testing Plan •  Section 7: User Guide Compliance •  Section 8: Project Management Plan

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1.0 Mission Overview

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Mission Overview

Our mission is a combination of two missions. One is to determine the durability of flexible electronics in the cryogenic environment of space. The second, is a test to create a de-spun video of the rocket flight. A flexible board will need to be tested in a variety of ways. A roll test, and a bend test in two directions will be performed and the experiment will be recorded by onboard video.

2013 CDR

Theory and Concepts

Flexible solar panels have been put up into space but we are testing the flexibility of electronic chips and their ability to function in the cryogenic environment.

2013 CDR

Mission Requirements: •  De-spun video

o  Goal: Record high quality video §  Will acquire a GoPro to record at 60fps 1020p §  Will be controlled via an Arduino

o  Goal: Data recovery §  Built in GoPro memory will be used

o  Goal: Write program to process video §  A team member will write a program to smooth video

•  Flexible electronics o  Goal: Design and manufacture substrate

§  Will work with ASI and at NNU to produce testable substrates o  Goal: Flex test electronic substrate

§  Will open door and flex substrate with 3 x 12v Motor/Encoders §  Will encase with aluminum to protect against harsh atmospheric conditions on return

o  Goal: Electronically test substrate §  Will use arduino to send test voltages §  Data will be recorded via telemetry lines

crestock.com

2013 CDR

Mission Requirements

•  Temperature o  Goal: Record temperature with a thermometer

§  Will use an Infrared thermometer §  Test the integrity of the thermometers at low temperatures §  The Arduino will be used as data collection

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Success Criteria:

•  Minimum success criteria o  De-spun video

§  A couple of seconds of video that has been de-spun would be the least amount of success for this subsystem to be considered a success.

o  Flexible electronics §  The minimal amount of success for this subsystem to

be considered a success is if data is gathered to prove or disprove the working of a flexible electronic board.

o  Thermometer §  Gather reasonable temperatures

2013 CDR

Expected Results

•  De-spun video •  At 60 fps during spin, a max of 5Hz, 12 pictures per rotation should

be acquired. •  Field of view angle must be greater than 30° to acquire

overlapping images which can be combined on an updated panorama.

•  Flexible electronics •  Bending may short components or break fragile connections. The

polymer may develop micro cracks or cracks large enough to be visible. Resistance of the wires may decrease due to cold but increase due to stretched connections.

•  Thermometer •  Low temperatures in the range of 1 to 5 K are expected

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Concept of Operations

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Example ConOps

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Concept of Operations

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2.0 Design Description

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Actions from PDR

•  Found prospective thermometer •  Met with ASI

o  Discussed flexible circuits

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Changes Since PDR

•  GoPro Hero 3 •  Flexible test circuit container •  Different degrees of motion on flexible

board •  LED light shining on flex board

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Design Overview: Functional Block Diagrams

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Mechanical Design Elements

•  Mechanical Subsystems o  Flexible Circuit Cylinder (Flex) o  GoPro Hero 3 Shields (GoPro) o  Arduino/PCB Cover (Ard)

•  Materials

o  Aluminum for Flex Circuit Cylinder o  Steel for the rest

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3D SolidWorks Designs

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Flexible Substrate Cylinder (Flex)

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GoPro Hero 3 Shield (GoPro)

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Arduino Box Shield (Ard)

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Meeting with American Semiconductors Inc

•  Thursday November 29th •  Presentation on various substrates and epoxies to test •  Size limits/requirements •  Materials

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Electrical Design Elements

•  Arduino o  Control power and other circuitry

•  I2C Temperature Sensor o  Infrared readings via I2C

•  H-Bridge Drivers o  Capable of drive motors in both directions

•  Logic Level Shifter o  Drop to a level for the FleX chips

•  Go Pro o  Records video

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System Electrical Diagram

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Software Design Elements

•  Since hardware has not yet been acquired, software has yet to be written. However, general concepts of design have been thought out.

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3.0 Subsystem Design

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Organizational Chart

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Despun Video

•  GoPro Hero 3 Black Edition •  Outward facing on baseplate •  Serial bus connection to Arduino

o  Begin filming commands •  Internal video storage •  Internal power •  Weight: .65lbf

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Flexible Systems

•  Flexible substrates and epoxies from ASI o  12v Motors controlled by arduino

•  GoPro Hero 3 camera o  Serial bus connected to Arduino o  DB37

•  Weight: 4.2 lbf

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Thermometer and Arduino System

•  Infrared Thermometer - MLX90614 •  Incorporated into Arduino •  Measure temperature of inner wall •  Determine temperature of reentry and space •  Weight: 4.37 lbf

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4.0 Prototyping/Analysis

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Analysis/Prototyping Results

•  Analysis to begin with 1st prototype in January •  Prototyping to begin in January •  Supplies from ASI for Flex

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Detailed Mass Budget

ExampleSat  Mass  Budget  Subsystem   Total  Mass  (lbf)  

Flex   3.3  GoPro   1.3  Ard   4.37  Base   3.425  

               

       Total   12.4  Over/Under   2.6  

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Detailed Power Budget

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Wallops Interfacing: Power

Power  Connector-­‐-­‐Customer  Side  Pin   FuncAon  1    Power  2    Shut  door,  motors  off  3      4    Open  door,  motors  on  5    GND  6      7      8      9      10  11      12      13      14      15      

•  Open door, motors flex 5 seconds later

•  Shut door motors off

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Wallops Interfacing: Telemetry

•  Motor encoder •  Temperature sensor •  Digital Circuit Testing

Telemetry  Connector-­‐-­‐Customer  Side  Pin   FuncAon   Pin   FuncAon  

1    Motor  encoder   20    Circuit  Test  2    Motor  encoder   21      3    Motor  encoder   22      4    Temperature   23      5       24      6       25      7       26      8       27      9       28      10       29      11       30      12    Circuit  Test   31      13    Circuit  Test   32      14    Circuit  Test   33      15    Circuit  Test   34      16    Circuit  Test   35      17       36      18       37      19              

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5.0 Manufacturing Plan

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Mechanical Elements

•  Purchased •  GoPro Hero 3 Black Edition •  Infrared Thermometer •  Motors •  Arduino

•  Manufactured •  Steel Storage Containers •  Flexible Substrate •  PCB

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Electrical Elements

•  PCB will be purchased assembled at NNU Power PCB may be separate depends on size

•  3 or 4 revisions are anticipated •  General parts for the PCB, motors need to be Procured •  Mid January motors will be purchased •  Early February parts for PCB should arrive

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Software Elements

•  Arduino code for motor, power control and temp sensor •  Flex electronic communication •  Telemetry Serial lines

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6.0 Testing Plan

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Mechanical Testing

•  Cold environment durability o  Fridge test

§  motors o  Dry ice test

§  electronics o  Liquid Nitrogen testing/play day

•  Spinning footage test •  Vibrational analysis test

o  Paint shaker •  Tests performed: February-March

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Electrical Testing

•  Test schematic with purchased components early February or components from lab will be tested

•  Simulations of the code •  Flight test in a balloon is possible late March, early April

2013 CDR

Software Testing

•  Simulate flight on components •  Test in balloon flight

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7.0 User Guide Compliance

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User Guide Compliance

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

plate?  1.2''  

Incorrect Materials

Max  Height  <  6"   Yes    

Within  Keep-­‐Out    Yes  

Using  <  10  A/D  Lines    Yes  

Using/Understand  Parallel  Line   Yes  

Using/Understand  Asynchronous  Line   Standard  Baud  

Using  X  GSE  Line(s)   2  

Using  X  Redundant  Power  Lines   1  (per  requirement)  

Using  X  Non-­‐Redundant  Power  Lines   2  (one  extra)  

Using  <  1  Ah   0.04  

Using  <=  28  V   12  

2013 CDR

Sharing Logistics

•  Who are you sharing with? •  Minnesota

•  The determination of the effect of a suborbital rocket flight on various electrical components due to radiation damage

•  Collaboration •  Email communication •  Design sharing via Solidworks

•  Interface

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8.0 Project Management Plan

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Schedule

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Budget

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Team Availability Matrix

•  Our classes have not been determined yet so this is not yet known

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Contact Matrix

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•  Past groups have shot footage on board. Was there any problems with misting? What material was used as lens?

• What are de-scopes and off ramps

Conclusion