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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. Mission Overview. 3. 4. 2. 5. 1. 6. Presenter: Eric Robinson. Mission Overview Scientific Mission .

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critical design review

Critical Design Review

Patrick Weber, Dorin Blodgett, Michael Stephens, Heather Choi,

Kevin Brown, Ben Lampe, Anne-Marie Suriano, Eric Robinson

November 19, 2010

slide2

Mission Overview

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Presenter: Eric Robinson

mission overview scientific mission
Mission OverviewScientific Mission

Primary: Collect space dust.

  • Provide a perspective of what is in our upper atmosphere.
    • Particle size = nano and micro level
    • Donate collected aerogel tablets to UW Geology Department for further analysis
      • SEM photographs of particle trails – velocity analysis
      • Identify particles – material property analysis

Secondary:

  • Capture optical images/video of the Earth.
  • Measure thermal and seismic effects throughout the duration of the launch.
    • Collect data for future projects.

Presenter: Eric Robinson

mission overview engineering mission
Mission OverviewEngineering Mission

Engineer an extendable boom to mount a dust collector.

Use aerogel and acrylic tablets as dust collectors.

    • Aerogel Density = 95 kg/m3
    • Acrylic Density = 1200 kg/m3
    • Engineer a water shield to protect dust collector.

Engineer modular electronic systems for:

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

Presenter: Eric Robinson

mission overview organizational chart
Mission OverviewOrganizational Chart

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

Charles Galey

Presenter: Eric Robinson

mission overview theory and concepts
Mission OverviewTheory and Concepts

Underlying Science and Theory

  • Attempt to capture space particles using telescoping boom, aerogel, and acrylic discs.
  • Quantification of varying flight parameters.

Presenter: Eric Robinson

mission overview theory and concepts1
Mission OverviewTheory and Concepts

Previous Experimentation

  • Previous flights have included multi-sensor packages.
    • Temperature, Humidity, and Pressure Sensors
    • Accelerometers / Seismic Sensors
    • Magnetometers
    • Data Storage (SD Cards)
  • Results provided a basis for improvement on future data collection and retrieval.
    • SD Cards impervious to low exposure to salt water
    • Payload electrical orientation

Presenter: Eric Robinson

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: Eric Robinson

mission overview expected results
Mission OverviewExpected Results

Successfully collect space dust

  • Space Dust Composition(10-6)
    • Exhausted Rocket Fuel
    • Meteor / Metal Fragments
    • Other Miscellaneous Gases
  • Detailed data throughout flight duration
    • Thermal Data
    • Seismic/Vibration Data
    • Earth images/video

Presenter: Eric Robinson

slide10

Design Description

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Presenter: Eric Robinson

design description design changes since pdr
Design DescriptionDesign Changes Since PDR

Payload water shield has been removed

  • Complex manufacturability
  • Electrical components do not need to be salvaged

New Telescopic Boom Control Mechanism

  • Steel tape reel design (akin to a tape measure)
  • New high torque gear box DC motor instead of stepper motor

Mission Objective Changes

  • Pressure sensors have been removed from secondary objective

Presenter: Eric Robinson

design description de scopes and off ramps
Design DescriptionDe-Scopes and Off-Ramps

De-Scopes

  • No mission objectives have been removed
  • All objectives are still considered feasible

Off-Ramps

  • We do not believe we will run into schedule/budget constraints that would require a contingency.

Presenter: Eric Robinson

design description subsystem overview
Design DescriptionSubsystem Overview

STR

Telemetry

Wallops

PWR

Wallops

Temp. Sensor

TB/STR

Interface

Aerogel

Accel.

Sensor

Motor

Boom

Boom

IS/STR

Interface

Optical Camera

Optical Camera

Arm Control

MCU

EPS/STR

Interface

OC/STR

Interface

EPS

TB

OC

IS

IS/EPS

Interface

Control Box

OC/EPS

Interface

TB/EPS

Interface

Optical Camera

Temperature Sensor

Accelerometers

Presenter: Eric Robinson

design description mechanical design elements2
Design DescriptionMechanical Design Elements
  • Retracted – 11 in boom
  • Extended – ~19 in boom – ~12 in reach

Presenter: Eric Robinson

design description electrical system components
Design DescriptionElectrical System : Components
  • 16G 2-Axis Accelerometer
  • Temperature Sensors
  • Motor Driver
  • Encoders
  • Power Regulators

Arduino Controller

5M Digital Camera

16 Mbit data flash

100:1 Metal gear motor

250 G Accelerometer

Presenter: Michael Stephens

design description electrical system arduino
Design DescriptionElectrical System : Arduino

Atmega 328 @ 16 MHz

32Kb of Program Storage

2KB of Ram

Digital Pins : 14

  • 6 PWM

Analog Pins : 6

  • 10 Bit
  • 10 KHz sample time

Provide control over payload

Presenter: Michael Stephens

design description electrical system xy accel
Design DescriptionElectrical System : XY Accel.

2 axis ± 18G

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

5V @ 350 µA

50 Hz cut off filter

Used last year as well

Provide acceleration in the non extreme XY axis.

Presenter: Michael Stephens

design description electrical system z accel
Design DescriptionElectrical System : Z Accel.

1 axis ± 250 G

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

5V @ 1.5 mA

400 Hz cutoff filter

Provide acceleration data in the extreme Z (up) axis

Presenter: Michael Stephens

design description electrical system motor
Design DescriptionElectrical System : Motor

100:1 gear ratio

140rpm @ 6V

6V @ 90mA

800mA stall current @ 6V

0.9375 in-lb motor torque @ 6V

Provide winding action of tape.

Presenter: Michael Stephens

design description electrical system motor driver
Design DescriptionElectrical System : Motor Driver

3 wire interface (In1, In2, PWM)

1.2 A max @ 15 V

Presenter: Michael Stephens

design description electrical system temp sensor
Design DescriptionElectrical System : Temp. Sensor

TMP36

-50C to 125C = 175C range

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

SLOW (300s for full range change)

5V @ .5uA

Presenter: Michael Stephens

design description electrical system optics
Design DescriptionElectrical System : Optics

DVR 623V 5M DSC/DV module

Presenter: Michael Stephens

  • 5.1 megapixel
  • Internal shutter trigger
  • SD Data up to 4GB
  • 5V @ ? mA
  • Provide photos/video of flight
design description electrical system flash storage
Design DescriptionElectrical System : Flash Storage

16 Mbit (2MB)

3.3V @ 7 mA

36 Kbytes/second write time

SPI Interface (4 digital pins)

Presenter: Michael Stephens

design description electrical system storage
Design DescriptionElectrical System : Storage

Used for redundant storage of acceleration data

Maximum sensor sampling time 400 Hz

3 x 10 bit = 30 bits ~ 4 bytes

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

Presenter: Michael Stephens

design description electrical system power
Design DescriptionElectrical System : Power

12 V regulators

6V regulators

780X series max input voltage 35 volts.

Presenter: Michael Stephens

design description electrical system encoder
Design DescriptionElectrical System : Encoder

Digital light sensor

2 Wires (1 enable, 1 output)

5V @ 25 mA

Used to sense black and white pattern on spool.

  • Used to detect stalls
  • Used to verify extension

Presenter: Michael Stephens

design description software design elements
Design DescriptionSoftware Design Elements

Programmed on Arduino in “C”

Heavy use of interrupts

Presenter: Michael Stephens

slide33

Prototyping/ Analysis

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Presenter: Patrick Weber

analysis results
Analysis Results

Telescopic Boom

  • Finite Element Analysis
    • Deflections, stress, and strain
  • Newtonian Laws

Payload Frame

  • Finite Element Analysis
    • Deflections, stress, and strain

Presenter: Patrick Weber

analysis results telescopic boom stress
Analysis ResultsTelescopic Boom - Stress

Key Results

Loading of 100G

Presenter: Patrick Weber

  • Stress
    • Peak von Mises
    • 11 MPa at truss convergence point
analysis results telescopic boom deflection
Analysis ResultsTelescopic Boom – Deflection

Key Results

Loading of 100G

Presenter: Patrick Weber

  • Deflection
    • 6061 Aluminum
      • 1.12E-2 mm at
      • center of boom.
    • 1023 Carbon Steel
      • 1.099E-2mm at
      • center of boom.
analysis results telescopic boom fos
Analysis ResultsTelescopic Boom – FOS

Key Results

Loading of 100G

Presenter: Patrick Weber

  • Factor of Safety
    • 6061 Aluminum
      • Min - 24.59
    • 1023 Carbon Steel
      • Min – 8.59
analysis results material decision
Analysis ResultsMaterial Decision

Material Strength

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

Material density

  • Aluminum 6061
    • ρ = 0.0975 lb/cu.in.
  • 1023 Carbon Steel
    • ρ = 0.284 lb/cu.in.

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

Presenter: Patrick Weber

analysis results material decision1
Analysis ResultsMaterial Decision

Aerogel Design

  • Results from aerogel studies have proven that an Aerogel Density of 95 kg/m3 will be sufficient in capturing the micro-scaled particles. [1]
  • [1] – Horz, Friedrich, Mark J. Cintala, Thomas H. See, and Keiko Nakamura-Messenger. "Penetration Tracks in Aerogel. Produced by Al2O3 Spheres." Meteoritics & Planetary Science.

Presenter: Patrick Weber

prototyping results
Prototyping Results

Most prototyping is theoretical and conducted using SolidWorks.

Further prototyping and testing will occur once the parts are manufactured and assembled.

  • Late January/Early February

Presenter: Patrick Weber

detailed mass budget
Detailed Mass Budget

Total Mass Budget (15±0.5 lbs)

  • Structure (5.95 lbs)
    • Boom (5.05 lbs)
    • Circuit Trays (0.9 lbs)
  • Camera (0.25 lb)
  • Other Sensors (1 lb)
  • Modular Electrical System (1 lb)
  • Ballasting (~6.80 lbs)

Presenter: Patrick Weber

detailed power budget
Detailed Power Budget

Presenter: Michael Stephens

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

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

wallops interfacing power
Wallops Interfacing: Power

Presenter: Michael Stephens

wallops interfacing telemetry
Wallops Interfacing: Telemetry

Presenter: Michael Stephens

slide45

Manufacturing Plan

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Presenter: Patrick Weber

manufacturing plan mechanical elements
Manufacturing PlanMechanical Elements

Payload Frame – 6061 Aluminum Alloy

  • Machined
  • Bolted together

Telescopic Boom – Precision DOM Aluminum Tubing

  • Boom Housing
    • Tubing with Epoxied Flange
  • Intermediate Arm
    • Epoxied Rail
  • Aerogel Arm
    • CNC machined from Aluminum Barstock
    • Aerogel Purchased

Parts submitted for machining by Tuesday, November 23rd

Presenter: Patrick Weber

manufacturing plan electrical elements
Manufacturing PlanElectrical Elements

Electrical Power System

  • Arduino Board

Integrated Sensors

  • Purchase

All wires will be soldered

All wires and boards will be epoxied to acrylic mounting plates.

  • Acrylic will comply with no-voltage requirement.

Parts ordered by Wednesday, December 1st.

Presenter: Michael Stephens

manufacturing plan software elements
Manufacturing PlanSoftware Elements

Software will be developed next semester starting mid-January 2011.

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

Software developed in Arduino “C” language.

Presenter: Patrick Weber

slide49

Testing Plan

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Presenter: Patrick Weber

testing plan system level testing
Testing PlanSystem Level Testing

Full mission simulation testing using physical model.

Vibration testing at the University as well as Wallops.

Boom extension/retraction test using electronics and mechanical models.

Payload drop testing

Thermal Expansion testing

Presenter: Patrick Weber

testing plan mechanical testing
Testing PlanMechanical Testing

Prove mechanical functionality on ground

Boom tests

  • Cyclic Extension/Retraction Tests
  • Friction Tests
  • Bending/Binding Tests
  • Tape Reel Buckling Strength Tests
  • Thermal Expansion Tests

Water sealant testing

  • Pool submersion test on canister
  • Drop impact test on canister sealing

Testing will be performed as models and utilities become available.

Presenter: Patrick Weber

testing plan electrical testing
Testing PlanElectrical Testing

Temperature sensor testing

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

Hot / Cold system test

  • Place entire system in oven, place outside. Examine for solder disconnects.

Accelerometer testing

  • Use elevators and cars to verify acceleration readings.

Presenter: Michael Stephens

testing plan software testing
Testing PlanSoftware Testing

Asynchronous data capture test

  • Run Sine wave into ADC. Verify consistent timing.

Motor control test

  • Extend boom
  • Retract boom
  • Verify extension and retraction and analyze fault conditions

Integration testing

  • Use sine wave generators as sensor inputs
  • Run simulated mission to detect possible data anomalies / control anomalies.

Multiple day in the life (DITL) tests on ground.

  • Simulate entire mission with actual sensors.

Presenter: Michael Stephens

slide54

Risks

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Presenter: Patrick Weber

risk walk down
Risk Walk-Down

Risk Matrix / Mitigation

  • STR/TB.RSK.1: Canister seals failat splashdown and aerogel issaturated with water.
  • TB.RSK.2: Boom jams when skinsare shed. Boom fails to open andmission objectives are not met.
  • 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.
  • 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.

Presenter: Patrick Weber

slide56

User Guide Compliance

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Presenter: Patrick Weber

user guide compliance
User Guide Compliance

Presenter: Patrick Weber

sharing logistics
Sharing Logistics

Who are we sharing with? – We don’t know.

  • University of Northern Colorado
  • Re-entry Experiment Sat: Recover a reusable deployable, attempt to dynamically control the descent of the payload, and gather data during the return trip.
  • The possibility of a communication system between the AstroX payload and the UNC Re-entry Experiment Sat payload is being considered.

Plan for collaboration?

  • Email, phone, road-trips to Greeley and Boulder
  • Communication with Max Woods on a weekly basis.
  • Grant UNC access to the AstroX private website.

Presenter: Patrick Weber

slide59

Project Management Plan

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Presenter: Patrick Weber

mechanical schedule
Mechanical Schedule

Major Mechanical Milestones:

  • Design Freeze at CDR (Friday, November 19, 2010)
  • Blueprints submitted for manufacturing on Nov. 23
  • Mechanical prototype constructed mid-January, 2011
  • Mechanical prototype fully tested by end of January, 2011
    • Impact and submersion testing
    • Aerogel testing

Presenter: Patrick Weber

electrical schedule
Electrical Schedule

Major Electrical Milestones:

  • Electrical Schematics completed by CDR
  • Components ordered by December 1
  • Electrical assembly and testing done by Mid February
    • Control function test
    • Telemetry and flash memory output test
  • Fully functioning payload by end of February

Presenter: Patrick Weber

monetary budget
Monetary Budget

Monetary Budget (~$1200)

  • Structure ($600)
    • Boom ($300)
    • Aerogel ($300)
  • Camera ($100)
  • Other Sensors ($110)
  • Modular Electrical System ($200)
  • Correcting Factor (+$20%)

Presenter: Patrick Weber

work breakdown structure
Work Breakdown Structure

Telescopic Boom (TB)

Electrical Power System (EPS)

  • Design Freeze at CDR
  • Order Parts by End of Fall Semester
  • Build Circuits
  • Program Microcontrollers
  • Test Systems
  • Integrate with Boom
  • Design Freeze at CDR
  • Submit Work Request
  • Manufacture Boom Parts
  • Assemble Boom and Structure

Integrated Sensors (IS)

Optical Camera (OC)

  • 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

Presenter: Patrick Weber

slide64

Conclusions

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Presenter: Patrick Weber

mission overview scientific mission1
Mission OverviewScientific Mission

Primary: Collect space dust.

  • Provide a perspective of what is in our upper atmosphere.
    • Particle size = nano and micro level
    • Donate collected aerogel tablets to UW Geology Department for further analysis
      • SEM photographs of particle trails – velocity analysis
      • Identify particles – material property analysis

Secondary:

  • Capture optical images/video of the Earth.
  • Measure thermal and seismic effects throughout the duration of the launch.
    • Collect data for future projects.

Presenter: Eric Robinson

mission overview engineering mission1
Mission OverviewEngineering Mission

Engineer an extendable boom to mount a dust collector.

Use aerogel and acrylic tablets as dust collectors.

    • Aerogel Density = 95 kg/m3
    • Acrylic Density = 1200 kg/m3
    • Engineer a water shield to protect dust collector.

Engineer modular electronic systems for:

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

Presenter: Eric Robinson