T EAM C HINESE B ANDIT O ZONE P AYLOAD C RITICAL D ESIGN R EPORT (CDR) Zach Baum Harry Gao Ryan Moon...
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Transcript of T EAM C HINESE B ANDIT O ZONE P AYLOAD C RITICAL D ESIGN R EPORT (CDR) Zach Baum Harry Gao Ryan Moon...
![Page 1: T EAM C HINESE B ANDIT O ZONE P AYLOAD C RITICAL D ESIGN R EPORT (CDR) Zach Baum Harry Gao Ryan Moon Sean Walsh 1.](https://reader030.fdocuments.net/reader030/viewer/2022033105/56649e895503460f94b8e1e5/html5/thumbnails/1.jpg)
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TEAM CHINESE BANDITOZONE PAYLOAD CRITICAL DESIGN REPORT (CDR)
Zach BaumHarry Gao Ryan MoonSean Walsh
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TABLE OF CONTENTS
Mission Goal Objectives Requirements Electrical Design Software Design Thermal Design Mechanical Design Payload Construction Plan Mission Operations Master Schedule Master Budget
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MISSION GOAL
Create a profile of ozone concentration with respect to altitude from ground level to 100,000ft.
Ozone sensor reading for 2012 UND/UNF HASP payload
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SCIENCE OBJECTIVES
Map peak of ozone concentration in upper atmosphere.
Create ozone concentration profile with respect to altitude.
Map out any fluctuations within ozone profile.
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TECHNICAL OBJECTIVES
The payload must measure ozone concentration
The onboard program will be able to: Take temperature readings
within close proximity to ozone sensor
Maintain proper operating temperature for all necessary components
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SCIENCE REQUIREMENTS
The payload must take measurements of ozone concentration every 3 seconds
Team Chinese Bandits must receive time and altitude GPS information for analysis from LaACES management
The payload must measure the peak ozone concentration to within .2ppmv
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TECHNICAL REQUIREMENTS The payload must: Not have a mass greater than 500g Not exceed 3oz/in2 on any surface Have two holes 17in apart through which the payload will interface
with the balloon Costs must remain within the allotted $500 budget for Chinese
Bandits In order for the payload to create an ozone profile of the
atmosphere, the following requirements must be met: Payload must take measurements of ozone concentration
throughout the flight Payload must be recovered for post-flight analysis Altitude must be known to within 65 feet For the accuracy to be known within 65 feet, the following
requirements must be met: Real-time clock must be synced with GPS time during pre-flight Real-time clock must be accurate to within 3 seconds of the
LaACES LASSEN iQ GPS
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SENSORSOZONE SENSORS
ITO acts as a variable resistor whose resistance changes in the presence of ozone Applying a constant current allows us to relate
the change in output voltage to the resistance and ozone concentration as measured by each sensor
Has a small operating temperature range, therefore a thermal controlling system will be needed
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SENSORSOZONE SENSORS
Calibration data will be obtained from Dr. Patel
The equation can be used to relate the resistance of each sensor to the ozone concentration Y = sensor resistance, X = concentration of
ozone, m = slope of the calibration curve, b= y-intercept of curve
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SENSORSTHERMISTOR
KC003T-ND thermistor
Property Value
Operating Temperature Range
-50°C - 150°C
R0 (Resistance at 25°C) 10 kΩ
Temperature Coefficient (@ 25°C)
-4.40%/°C
Accuracy (@ 25°C) +/- 1°C
Resistance at 20°C 12.5 kΩ
Resistance at 30°C 8.055 kΩ
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HEATER KHLV-101/5 Kapton Heater 1in. X 1in. Provides up to 5W of heat with 28V max
voltage Property Value
Resistance 150 Ω
Current draw 80 mA
Power draw 0.936 W
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SENSOR INTERFACINGOZONE SENSOR
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OZONE SENSOR INTERFACING Zero temp-
coefficient circuit for the constant current sourceResistor
value (Ω)LM234 current output (mA)
0 2.5
10 2.5
100 2.5
600 2.5
1000 2.5
1400 2.5
1500 2.5
1600 2.5
2000 2.5
2400 2.5
2800 2.5
3200 2.24
3600 1.48
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THERMISTOR INTERFACE
Different constant current, op amp
Output voltage Thermistor resistance
3V 12.5KΩ
.2V 6.5KΩ
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CONTROL ELECTRONICSBASIC STAMP PIN LAYOUTPin no. Pin Function Pin no. Pin Function1 Serial Out 13 I/O (EEPROM)2 Serial In 14 RTC (EEPROM)3 ATN 15 Reset RTC4 Vss 16 DATA (RTC)5 Data Output
(ADC0838)17 I/O (RTC)
6 RTC (ADC0838) 18 Data Output (ADC0834)
7 CS (ADC0838) 19 RTC (ADC0834)8 NA 20 CS (ADC0834)9 LED Output 21 VDD 10 LED Output 22 RES11 LED Output 23 Vss12 LED Output 24 VIN
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CONTROL ELECTRONICSADC0838 PIN LAYOUT
Pin no. Function Pin no. Function
1 CH0 11 Analog Ground
2 CH1 12 VREF
3 CH2 13 Shift Enable
4 CH3 14 DO
5 CH4 15 SARS
6 CH5 16 CLK
7 CH6 17 DI
8 CH7 18 CS
9 COM 19 V+
10 Digital Ground
20 VCC
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CONTROL ELECTRONICSCIRCUIT INTERFACING
Sensor Board (16 card edge connector)
16 wire Ribbon Cable
Conditioning Board (8x2 pin Header)
16 S1 1 S114 S2 2 S212 S3 3 S310 S4 4 S48 S8 5 S86 S7 6 S74 S6 7 S63 Common 8 C2 S5 9 S5*Other pins not used
*Other pins not used
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CONTROL ELECTRONICSCIRCUIT INTERFACINGConditioning Board (13x1 pin header)
26 wire Ribbon Cable
BalloonSat (13x2 pin header)
1 Vcc (5V in) 1 Vcc (5V in)2 Vref (3V ref.) 3 Vref (3V ref.)3 ADC0
(Thermistor I/O)
5 ADC0 (Thermistor I/O)
4 Not used 7 Not used5 Not used 9 Not used6 Not used 11 Not used7 P0 (I/O ITO) 13 P0 (I/O ITO)8 P1 (RTC
ADC0838) 15 P1 (RTC
ADC0838)9 P2 (CS
ADC0838) 17 P2 (CS
ADC0838)10 P3 (3V Vref.) 19 P3 (3V Vref.)*Other pins not used
All Even pins Ground*Other pins not used
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POWER SUPPLY AND DISTRIBUTION
Two power sources: one 9V, one 12V
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HEATER AND RELAY CONFIGURATION
Will Use a 2N3904 transistor as a relay BASICStamp will send 3V to base pin to
saturate it, allowing the 12V load to flow through the transistor and power heater
10KΩ resistor placed before the base pin will limit the base current that can flow into the transistor
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POWER BUDGETPower Budget
Consumer Consumption Rate
Voltage Energy
Ozone Sensors
1 mA * 8 sensors = 80
mA
Variable (depende
nt on sensor, 3V
max)
400 mAh
Thermistor .01 mA 3 V .05 mAh
Heater 80 mA 12 V 400 mAh
Balloon Sat 53 mA 9 V 265 mAh
Total 213.01 mA 1065.05 mAh
Power Supply 1
Power Supply 2
Needed capacity
665.05 mAh
400 mAh
Required Voltage
9 V 12 V
AA Lithium Ion
Voltage (per battery)
1.5 V
Capacity(per battery)
3000 mAh
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THERMAL DESIGNLaACES Thermal Flight Isun 1377.0 W/m2
Earth-Space Parameters
UNITS Latitude 31 degrees
Stefan-Boltzmann5.67E-
08W/m2
K4 T-float 210 K
Isun (solar constant) 1377 W/m2 Albedo 0.5
T-space 4 K Day of year 141 day
Flight altitude 30500 m Hour of day 14 hr
Earth orbit eccentricity 0.01672 Declination angle 19.91164 deg
T-earth 273 K Inclination angle 29.14873 deg
R-earth638000
0 m IR Fluxmin 160 W/m2
Payload Parameters Internal Heat 2.96 WView factor payload-earth 0.451 Effective Isolar 1360.54 W/m2
View factor payload-space 0.700
Effective Isphere 339.12 W/m2
Sphere radius 0.103 mENERGY BALANCE calculations
bladder thickness 0.000 m Qsun 15.824 W
kevlar shell thickness 0.000 m Qalbedo 13.861 W
bladder conductivity 0.026 W/mK Qpower 2.960 W
kevlar shell conductivity 0.040 W/mK Q-IR 2.046 W
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THERMAL DESIGNInsulation Parameters Total input: 34.690 W
insulation absorptivity 0.350 hrad,earth 1.862 W/m2 K
insulation thickness 0.019 m hrad,space 0.769 W/m2 K
insulation emissivity 0.850 constant1 0.248 W/K
insulation conductivity 0.027W/mK constant2 0.103 W/K
Area Calculations constant3 0.053 W/K
Total sphere projected area
3.33E-02 m2 Qrad-to-earth 2.295 W
Total sphere surface area
1.33E-01 m2 Qrad-to-space 28.542 W
Qconv-at-float 3.853 W
Total output: 34.690 W
Ti outer 9.2 degC
Ti inner 22.5 degC
Tk inner 22.5 degC
Tb inner 22.5 degC
Tavg interior air 24.7 degC
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MECHANICAL DESIGN
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WEIGHT BUDGETComponen
tQuantit
yMass Uncertain
tyCalculate
d/Measure
dBalloonSa
t1 68.9g +/- 0.05g Measured
Lithium AA
Batteries (9V total
unit)
6 88.3g +/- 0.1g Measured
Lithium AA
Batteries (12V total
unit)
8 117.9g +/- 0.1g Measured
FOAMULAR Casing
1 57.5g +/- 2 g Calculated
ITO sensor 1 13g +/- 0.1g Measured
Total 345.6g +/- 2 g
Component Approximate Mass
Operational Amplifier
57g
Sensor Interface
15g
Electrical Wiring
15g
Heater and Thermistor
10g
Glue, Paint,
Structural Component
s
10g
Total 112g
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PRE-FLIGHT SOFTWARE
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PRE-FLIGHT SOFTWARE: INITIALIZATION STAGE
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PRE-FLIGHT SOFTWARE: TESTING STAGE
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FLIGHT SOFTWARE
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FLIGHT SOFTWARE SUBROUTINES
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FLIGHT SOFTWARE SUBROUTINES CONT.
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POST FLIGHT SOFTWAREByte Offset
Data Description
0 Hour Timestamps the Data1 Minute2 Second3 ITO1 Reads ozone
concentration4 ITO25 ITO36 ITO47 ITO58 ITO69 ITO710 ITO811 Thermistor Reads temperature
of ITO Array
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PAYLOAD CONSTRUCTION PLAN
HARDWARE FABRICATION AND TESTING
Full system testing will be conducted after each subsystem is tested and proven
Payload design will be updates after testing A delay in any subsystem will cause
combined testing to be delayed
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INTEGRATION PLAN
After each subsystem is tested, individual systems will be connected together to ensure interfaces work properly
Electrical/software interfacing has been tested and proven
Tests on interfacing electrical, mechanical, and thermal will ensure proper operation temperature can be maintained
Testing will be done on all systems in a simulated flight to complete payload integration
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FLIGHT SOFTWARE IMPLEMENTATION AND VERIFICATION
Flight software was tested with electrical prototypes to ensure it was functioning correctly
Pre-Flight will be loaded the day before flight to clear EEPROM and sync GPS time to RTC
A computer located on site will be used to run programs and retrieve data
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FLIGHT CERTIFICATION TESTING
Tests will be conducted to ensure payload can survive flight
Temperatures of -70°C to 30°C Pressure of .163mBar to 1000mBar Impact upon landing A shock test and a thermal/vacuum test will
be conducted
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SYSTEM TESTING PROCEDURE
Payload needs to survive 8.94 m/s
H = 4.08m or 13.38 ft. Procedure checklist
Power up payload Run preflight software Run flight software Drop from13.4 feet onto the floor Run post-flight software Verify that all onboard electronics are operating
properly
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VACUUM TEST PROCEDURES
Power up payload Run preflight software Run flight software Place payload in Vacuum Testing Chamber Make sure that vacuum chamber is sealed and
pressure gauge is turned on Simulate flight environment in vacuum testing
chamber. This include having a temperature range -70
to 30C This include pressure of .163 mBar- 1000 mBar
Run post-flight software Analyze and verify data
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SYSTEM TESTING RESULTS
Preliminary tests done to test if sensors will work
Spark gap created in box to create ozone
ITO warmed to operating temperature and placed in box until 480 seconds
1 39 77 1151531912292673053433814194574955335710.0
100.0
200.0
300.0
400.0
500.0
600.0Resistance vs Time
Resistance
Seconds After Beginning Test
Chan
ge in
Res
istan
ce o
f orig
inal
val
ue o
f 1.4
kΩITO warmed to 25°C
ITO placed in box
ITO removed from box
After speaking with Dr. Patel, long reaction times may be due to not enough ozone to fully react, or not enough airflow across the sensor
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PRE-LAUNCH REQUIREMENTS AND OPERATIONS:CALIBRATIONS
Two Instruments that require calibration Thermistor
Calibrate for low temperature of 20°C Calibrate for high temperature range of 35°C
ITO Sensor Do not have necessary equipment to calibrate Will be provided by Dr. Patel of the University of
North Florida
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PRE-LAUNCH REQUIREMENTS AND OPERATIONS:CALIBRATION PROCEDURES
Thermistor Fill glass with cold water in a heat metal
container Place thermometer and thermistor Record the sensor reading using the voltmeter
and flight software for temperature from 20°C to 35°C
ITO Will be provided by Dr. Patel
ITO Circuit Thermistor Circuit
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PRE-LAUNCH CHECKLISTEvent Time Time
NeededMaterials Needed
Verify all systems are flight ready
2 days before flight
20 minutes
The full Chinese Bandits payload, multimeter
Run Pre-Flight Software
12 hours before flight
15 min. The full Chinese Bandits payload, one computer with BASIC Stamp Editor software, one 9-pin serial
cableSet time of BalloonSAT
clock
12 hours before flight
15 min. The full Chinese Bandits payload, one computer with BASIC Stamp Editor software, one 9-pin serial cable, the LaACES GPS unit with
computer hookupsReplace battery
packs with fresh, tested
packs
12 hours before flight
5 min. Fresh, tested 9 and 12 volt battery packs
Load Flight Software onto the BalloonSat
12 hours before flight
5 min. The full Chinese Bandits payload, one computer with BASIC Stamp Editor software, one 9-pin serial
cableConnect battery packs, close and seal payload lid
1 hour before flight
5 min. Tape
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FLIGHT REQUIREMENTS, OPERATIONS AND RECOVERY
Batteries will provide the BalloonSat and sensors with enough power for the duration of the flight
EEProm will have enough memory to take measurements for the duration of the flight
Must find and recover EEProm during recovery; Extra BallonSats will be brought in order to retrieve the data from the EEProm
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DATA ACQUISITION AND ANALYSIS
PLAN: GROUND SOFTWARE The following procedure will
be used to complete Ground Software andexport flight data.
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DATA ACQUISITION AND ANALYSIS PLAN:DATA ANALYSIS PLAN
ADC values will be converted into ozone measurements in PPM(Parts Per Million)
Thermistor values will be converted to degrees in Celsius
Sync GPS value with time to get altitude data
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DATA ACQUISITION AND ANALYSIS PLAN:DATA ANALYSIS PLAN (CONTINUED)
The following graphs will be made from flight data to help with the analysis process Ozone vs. altitude Ozone vs. time Temperature vs. time Ozone vs. temperature
Expected uncertainties for thermistor will be 1 percent while the uncertainties for the ozone sensor will be 0.2ppm
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PROJECT MANAGEMENTWBS
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PROJECT MANAGEMENTWBS
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PROJECT MANAGEMENTWBS
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STAFF ORGANIZATION AND RESPONSIBILITIES
Category Team Member
Project Manager Zach Baum
Software Developer and Lead
Harry Gao
Mechanical Lead Sean Walsh
Electrical Lead Harry Gao
Calibrations Harry Gao
Integration Zach Baum
Version Control and Editing
Ryan Moon
System Testing Sean Walsh
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MASTER BUDGETEXPENDITURE PLAN
Quantity Part no. Description Unit Price Total PriceParts For Testing (1)
1 ADC088S102CIMT/NOPB-ND
8 channel ADC
$3.09 $3.09
1 LM234Z-6/NOPB-ND
Constant Current Source
$1.27 $1.27
1 AT24C512C-SSHM-B-ND
64KB EEPROM $1.76 $1.76
2N7002K-T1-E3CT-ND
Transistor for relay
$0.38 $0.38
KHLV-101/5 Heater $31.00 $31.00 Shipping
Total$18.99
Parts For Testing (2)
1 TIP112TU-ND
Transistor for relay
$0.66 $0.66
1 24LC512-I/P-ND
64KB EEPROM $1.96 $1.96
1 ADC0834CCN/NOPB-ND
4 Channel ADC
$3.11 $3.11
1 LM234Z-6/NOPB-ND
Constant Current Source
$1.27 $1.27
1 ADC0838CCN/NOPB-ND
8 channel ADC
$2.97 $8.91
1 ITO Sensor for Testing
Ozone Sensor Borrowed $0.00
Shipping Total
$14.94
Total $86.33
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MASTER BUDGETEXPENDITURE PLAN
Parts for Fabrication
24 AA Energizer L91 batteries
Batteries for power supply
$49.95 for 24-pack
$49.95
6 AD822ANZ-ND Op-Amp for ITO’s
$6.28 $37.68
2 AD820 Op-Amp for Thermistor
$4.54 $9.08
18 3299W-104LF-ND
Variable resistor $2.60 $46.80
12 LM234Z-6/NOPB-ND
Constant Current Source
$1.27 $15.24
2 TIP112TU-ND Transistor for relay
$0.66 $1.32
1 KHLV-101/5 Back-up heater $31.00 $31.00 1 24LC512-I/P-
NDBack-up EEPROM
$1.96 $1.96
1 PCB Printed Circuit Board
$177.70 $177.70
1 Flight-ready ITO sensor
Borrowed $0.00
12 445-5327-ND 10microF capacitor
$0.46 $5.52
1 Pack of Real Velcro
$8.14 $8.14
Shipping Total $18.99
Total $416.85 Total Expected
Expenditure $502.18
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MASTER BUDGETMATERIAL ACQUISITION PLANMaterial Qua
ntities
How Acquired
When Needed
When to Order
BalloonSat 1 Supplied by LaACES
Calibration and testing
Already Have
Capacitors, resistors, wires, etc
x Supplied by LaAces
Calibration and testing
Already Have
ADC088S102CIMT/NOPB-ND8 channel ADC
1 Ordered from Digikey
Calibration and testing
Already Have
LM234Z-6/NOPB-NDConstant Current Source
12 Ordered from Digikey
One for Calibration and testing, the rest for fabrication
1 week before fabrication
AT24C512C-SSHM-B-ND64KB EEPROM
2 Ordered from Digikey
One for Calibration and testing, the other for backup
Need 1 more
2N7002K-T1-E3CT-NDTransistor for relay
1 Ordered from Digikey
Calibration and testing
already have
KHLV-101/5Heater
1 Ordered from Omega
Calibration and testing
already have
TIP112TU-NDTransistor for relay
1 Ordered from Digikey
Calibration and testing
already have
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MASTER BUDGETMATERIAL ACQUISITION PLAN24LC512-I/P-ND64KB EEPROM
1 Ordered from Digikey
Calibration and testing
already have
ADC0834CCN/NOPB-ND4 Channel ADC
1 Supplied by LaAces
Calibration and testing
already have
LM234Z-6/NOPB-NDConstant Current Source
1 Ordered from Digikey
Calibration and testing
already have
ADC0838CCN/NOPB-ND8 channel ADC
1 Ordered from Digikey
Calibration and testing
already have
ITO Sensors 1 Borrowed from Dr. Patel
Calibration and testing
already have
AA Energizer L91 batteriesBatteries for power supply
24 Order Online through Amazon
Fabrication Need to order 1 week before fabrication
AD822ANZ-NDTable 22: Material Acquisition Plan
Op-Amp for ITO’s
6 Ordered from Digikey
Fabrication Need to order 1 week before fabrication
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RISK MANAGEMENT AND CONTINGENCY PLANSystem Risk Contingenc
y PlanTrigger Who is
responsible
Electrical Not returning correct data
Calibration and testing in simulated conditions
Changes in output related to unexpected conditions
Team
Electrical Interface and component problems
Testing components hardware and software before, during, and after assembly
Faulty wiring and components
Harry
Mechanical Inclement weather
Structurally sound and sealed mechanical design and testing
Weather Sean/Ryan
Electrical/Mechanical
Inability to maintain operating temperature
Using a heater and thermistor, testing in simulated flight conditions
Extreme cold Team
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RISK MANAGEMENT AND CONTINGENCY
Electrical Frying EEPROM
Have back-up parts, and use extreme caution pre-flight
Carelessness
Zach
All systems Loss of payload
Prepare failure report
Loss of payload during flight
Team/LaACES staff
All systems Loss of team member
Rest of team would pick up responsibilities
Increased workload
Team
Project Management
Not meeting deadlines
Set early deadlines to allow for mistakes to be fixed
Poor project management
Zach
All systems Over budget Find cheaper and more cost-effective components
Not enough money
Team