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Individual Subsystem Testing Report. Patrick Weber, Michael Stephens, Heather Choi, Kevin Brown, Ben Lampe , Anne-Marie Suriano , Eric Robinson, Dorin Blodgett. February 24, 2011. Mission Overview. 3. 4. 2. 5. 1. 6. Presenter: Dorin Blodgett.

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individual subsystem testing report

Individual Subsystem Testing Report

Patrick Weber, Michael Stephens, Heather Choi, Kevin Brown,

Ben Lampe, Anne-Marie Suriano, Eric Robinson, Dorin Blodgett

February 24, 2011

slide2

Mission Overview

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2

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Presenter: Dorin Blodgett

mission overview scientific mission
Mission OverviewScientific Mission

Primary: Collect space dust.

  • Particle size = nano and micro level
  • Space Dust Composition (10-6)
    • Exhausted Rocket Fuel
    • Meteor / Metal Fragments
    • Other Miscellaneous Gases
  • Donate collected aerogel tablets to UW Geology Department for further analysis

Secondary:

  • Capture Detailed data throughout flight duration
    • Thermal Data
    • Seismic/Vibration Data
    • Earth images/video

Presenter: Dorin Blodgett

mission overview engineering mission
Mission OverviewEngineering Mission

Engineer an extendable boom to mount a dust collector.

Use aerogel as dust collectors.

Engineer modular electronic systems for:

  • Capturing and storing images from optical devices.
  • Actuating Telescopic Boom
  • Recording thermal and seismic data in real time throughout launch using sensors and transferring recording data via provided NASA Wallops Telemetry.

Presenter: Dorin Blodgett

mission overview concept of operations
Mission OverviewConcept of Operations

t ≈ 1.7 min

Shedding of Skin

Boom Extends via First Timed Event

t ≈ 4.0 min

Boom Retractsvia Arduino Controller

Boom Power Shut Down

t ≈ 2.8 min

Apogee

t ≈ 0.7 min

End of Orion Burn

t ≈ 15 min

Splash Down

Payload Power Down

t ≈ 8.2 min

Chute Deploys

t ≈ 0 min

Launch

Systems Power On (t = -2 min)

-Collection of Sensor Data Begins

Presenter: Dorin Blodgett

design description subsystem overview
Design DescriptionSubsystem Overview

STR

OC/STR

Interface

EPS/STR

Interface

Telemetry

Wallops

PWR

Wallops

Optical Camera

Temp. Sensor

Accel.

Sensor

IS/STR

Interface

Boom

Boom

Motor

Optical Camera

Arm Control

MCU

Aerogel

TB/STR

Interface

EPS

TB

OC

IS

Control Box

IS/EPS

Interface

OC/EPS

Interface

TB/EPS

Interface

Optical Camera

Motor

Temperature Sensor

Accelerometers

Presenter: Dorin Blodgett

slide7

Design Description/

Design Changes

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Presenter: Dorin Blodgett

design description new design parameters
Design DescriptionNew Design Parameters

Full Canister Available

  • 30 ± 1 lb weight requirement
  • Payload material changed to Steel
    • Payload – 16.7 lb
    • Ballast – 13.3 lb
  • Higher centrifugal forces
    • More powerful motor needed - holding torque of 57.6 lbin
    • Load increased on tape reel
      • Loading Stress – 16.5 ksi
      • Axial Deflection – 5.93E-4 in
      • Boom Seal
        • Tapered Seal
        • O-ring (Durometer Shore A:70)

Presenter: Dorin Blodgett

design description new design parameters1
Design DescriptionNew Design Parameters

Skin Ejection

  • Clam-like skin shed after motor burn-out
  • Payload section will not be pressurized

Temperatures at Reentry

  • Max of 350oF – well after apogee
  • Bearing material changed to Teflon
    • Higher operating temperature is 500F, melting of 635F
  • Radial thermal expansion, Δ T of 273F
    • Teflon = 3.3E-2 in
    • Steel = 3.3E-3 in
  • High temperature o-ring (A:70)
  • Aerogel cover over electric components

Presenter: Dorin Blodgett

design description new design parameters2
Design DescriptionNew Design Parameters

Boom Vacuum

  • Boom will be pre-vacuumed prior to launch
  • Atmospheric pressures will ensure internal vacuum during reentry
  • Vacuum will aid in holding boom closed

Aerogel Contamination

  • Aerogel tablets will be inserted in clean room
  • Boom will be vacuumed
  • Aerogel Properties
    • Pore Network is open

Presenter: Dorin Blodgett

design description program management
Design DescriptionProgram Management

Project Manager

Shawn Carroll

Engineering Faculty Advisor

Dr. Carl Frick

Physics Faculty Advisor

Dr. Paul Johnson

Team Leader

Patrick Weber

Telescopic Boom (TB)

Patrick Weber

Eric Robinson

Dorin Blodgett

Electrical Power System (EPS)

Michael Stephens

Ben Lampe

Integrated Sensors (IS)

Michael Stephens

Heather Choi

Optical Camera (OC)

Kevin Brown

Nick Roder

No Changes

Presenter: Dorin Blodgett

design description program management1
Design DescriptionProgram Management

Team Picture

Presenter: Dorin Blodgett

design description program management2
Design DescriptionProgram Management

Schedule Update

  • Manufacturing delay (approval for construction)
  • Electrical manufacturing is on schedule and has begun assembly

Resolve Issues

  • Final drawings will soon be submitted to machine shop
  • Manufacturing should be done in two weeks

Concerns

  • Will a vacuum/ clean room be available at Wallops?

Presenter: Dorin Blodgett

slide14

Design Analysis

Subsystem Updates

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Presenter: Eric Robinson

design analysis subsystem list
Design AnalysisSubsystem List

Telescopic Boom (TB)

Optical Camera (OC)

Integrated Sensors (IS)

Electrical Power System (EPS)

Presenter: Eric Robinson

design analysis tb boom force parameters
Design Analysis - TBBoom Force Parameters

Forces on Boom - Testing on Earth

Presenter: Eric Robinson

design analysis tb boom force parameters1
Design Analysis - TBBoom Force Parameters

Forces on Boom – Throughout Launch

Presenter: Eric Robinson

design analysis tb boom force parameters2
Design Analysis -TBBoom Force Parameters

Force Ranges

through Launch

Force Ranges

through Reentry

Presenter: Eric Robinson

design analysis tb motor parameters
Design Analysis -TBMotor Parameters

Torque Load on Motor Throughout Launch

Presenter: Eric Robinson

design analysis tb payload boom lengths
Design Analysis -TBPayload Boom Lengths
  • Retracted –
    • 11.4 in boom
  • Extended –
    • 27.1 in boom
    • 14.6 in reach

Presenter: Eric Robinson

design analysis tb telescopic boom stress
Design Analysis -TBTelescopic Boom - Stress

Key Results

Loading of 50G in all directions and 100G vertical impulses

Presenter: Eric Robinson

  • Stress
    • Peak von Mises
    • ~1350 psi at Motor Support
    • Verified with Empirical Models
design analysis tb telescopic boom deflection
Design Analysis - TBTelescopic Boom – Deflection

Key Results

Loading of 50G in all directions and 100G vertical impulses

Presenter: Eric Robinson

  • Deflection
    • Peak Deflection
    • 0.24 thousandths ofan inch
    • Occurs at center ofboom.
slide25

Subsystem Testing

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Presenter: Patrick Weber

subsystems testing tests to be performed
Subsystems Testing Tests to be Performed

TB

  • Mechanical Test
    • Tape – reel buckling test Completed
    • Vibration test Not Completed
    • Drop impact test Not Completed
    • Water seal test Not Completed
    • Thermal expansion test Not Completed
    • Cyclic extension/retraction test Not Completed

Presenter: Patrick Weber

subsystems testing tests to be performed1
Subsystems Testing Tests to be Performed

EPS/ IS/OC

  • Electrical Test
    • Temperature sensor functionality test In Progress
    • Accelerometer functionality test Not Completed
    • Optical camera functionality test Not Completed
    • Thermal loading on electronics test Not Completed
  • Software Test
    • Asynchronous data capture test Not Completed
    • Motor control test Not Completed
    • Integration test Not Completed
    • Data recovery test Not Completed

Presenter: Patrick Weber

subsystems testing tb tape reel buckling test
Subsystems Testing - TBTape-reel Buckling Test

Key Results (14” Tape – reel)

Bucking Load with respect to

Tape – reel Length

Presenter: Patrick Weber

  • Extension load - earth
    • 0.23 lbf
  • Buckles loading of
    • 16.28 lbf
slide29

Subsystem Integration

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Presenter: Patrick Weber

subsystem integration plan
Subsystem IntegrationPlan

Based on where you are now, how will you ensure the subsystems will be integrated and tested for the Subsystem Integration and Testing Report?

  • Manufacture Payload
  • Assembly Payload
  • Test Payload

What are the major hurdles going to be?

  • Approval for Construction/ME Faculty
  • Part Backorder/Wait Time

Presenter: Patrick Weber

subsystem integration lessons learned
Subsystem IntegrationLessons Learned

What have you learned about subsystem testing and engineering so far?

  • The payload is over-engineered

What would you do differently?

  • Push ME Faculty harder for approval for construction

What has worked well so far?

  • We have analytical justification for all models

Presenter: Patrick Weber

slide32

Fabrication and Assembly

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Presenter: Patrick Weber

fabrication and assembly mechanical fabrication
Fabrication and AssemblyMechanical Fabrication

Payload Frame – 1018 Carbon Steel

  • CNC machined
  • Bolted down to base

Telescopic Boom –1018 Carbon Steel

  • Boom Housing
    • Tubing epoxied into frame
  • Intermediate Arm
    • Threaded tubing and bearing mounts
    • Teflon bearing
  • Aerogel Arm
    • CNC machined
    • Aerogel Purchased
  • Tape Reel housing
    • CNC machined
    • Bolted to frame

Presenter: Patrick Weber

fabrication and assembly mechanical assembly
Fabrication and AssemblyMechanical Assembly

Manufacturing Instructions

Presenter: Patrick Weber

detailed mass budget
Detailed Mass Budget

Total Mass Budget (30±1 lbs)

  • Structure (16.7 lbs)
    • Boom (13.7 lbs)
    • Circuit Trays (2.99 lbs)
  • Camera (0.25 lb)
  • Other Sensors (1 lb)
  • Modular Electrical System (1 lb)
  • Ballasting (13.3 lbs)

Presenter: Patrick Weber

monetary budget
Monetary Budget

Monetary Budget (~$1300)

  • Structure ($675)
    • Boom ($300)
    • Aerogel ($375)
  • Camera ($100)
  • Other Sensors ($110)
  • Modular Electrical System ($225)
  • Contingency (+$15%)

Presenter: Patrick Weber

slide37

Conclusions

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Presenter: Patrick Weber

conclusions
Conclusions

New Design Parameters Effects on Design

  • Reentry temperatures of 350oF – Teflon Bearings
  • Boom vacuum created before launch and at reentry
    • Prevent aerogel contamination
  • Full canister available
    • Payload made of 1018 Carbon Steel –
      • Less ballasting but greater centrifugal forces
      • Motor must withstand a holding torque of 57.6 lbin
    • New tape reel and frame design will survive loadings

Fabrication and Assembly

Vacuum/Clean room availability

Presenter: Patrick Weber