Mitchell Aerospace and Engineering Mitchell Community College November 30, 2011 Critical Design...

Mitchell Aerospace and Engineering Mitchell Community CollegeNovember 30, 2011

Critical Design Review

RockSat- C

Mission OverviewMission Overview

Design DescriptionDesign Description

Prototyping/AnalysisPrototyping/Analysis

Manufacturing PlanManufacturing Plan

Testing PlanTesting Plan

Outline of Presentation Outline of Presentation

RisksRisks

User Guide and Compliance User Guide and Compliance

Project Management Plan Project Management Plan

Mission OverviewErin Wilson

Mission OverviewMission OverviewGoal Statement:

Our goal is to design and implement various generators to

passively collect energy for possible use for space based

instrumentation. We expect to harvest energy from the flight

of the rocket, solar, magnetic and other various sources.

Mission OverviewMission Overview

Mission Requirements: For each transducer, voltage across a known resistor will

be measured and data will be stored.

○ Some transducers may require amplification of voltage.

The power used by COTS sensing package will be

measured and stored.

Measurable data from the COTS sensing package will be

saved.

Mission OverviewMission Overview

Discovery & Benefit:

Expect to transduce available energy to electrical energy

and possibly provide significant energy to supply space

based instrumentations.

Results may lower cost and power requirements for space

science by reducing the weight of electrical system.

Mission OverviewMission Overview

Organizational Chart

Doug KnightPh.D

Gary StaggersMechanicalManager

Erin WilsonSafety Officer

Beau BrinkleyProject Manager

Dylan StobbeElectricalManager

MichaelBrown

John BenfieldTest Manager

BradleyHager

RyanHoward

NathanKeller

DerekSpencer

JosephEdwards

Mission OverviewMission OverviewConcepts of Operations

T= 0

T= 0.6

T= 2.8

T= 5.5

T= 15

T= 0 min, Launch:G-switch triggered, Arduino countdown

program starts. Voltage from transducers is measured and read. Sensor data is recorded to microSD card.T= 0.6 min, End of Orion Burn: Systems functioning.T= 2.8 min, Apogee:

Systems functioning. Rocket begins its descent.T= 5.5 min, Chute Deploys: All systems functioning. Parachute ejection causes rapid change in rocket's motion.T= 15 min, Splash Down: Sensors remain functioning collectingenergy from impact. Countdown ends approximately one minute after splash down.

Expected ResultsExpected Results

Design DescriptionMechanical

Michael Brown

Mechanical Design Mechanical Design

De-Scopes & Off Ramps

Most transducers are to be completed as designed.

Diving Board may off ramp from a piezoelectric cantilever

beam to an aluminum beam with externally mounted piezo

actuator, based on budget constraints.

Full scale rocket has been de-scoped to a kit as opposed to

a custom build.

May implement a fractal design coil to harvest the earth’s

electromagnetic field.

Mechanical Design Mechanical Design

Dimensions of Diving Board

Neodymium Block: 1/4” x 1/4” x 1/2”

Cristal Quartz Cantilever: 1” x 3” x 1/4”, 1/2” x 3/4” (notch

removed)

6061 Aluminum Base: 1/2” x 1” x 1” base; 1/4” x 1” x 1” cap

30 Gauge Magnet Wire Coil: 1/4” x 5/8” diameter

Mechanical Design Mechanical Design

Dimensions of EM Pendulum

Bowl

○ Height: 1 1/4”, Top: 2 1/2”, Bottom: 0.500”

Magnet

○ Height: 0.88”, OD: 0.39”

Ball Joint

○ Plate: 0.40”, 30 Gauge Magnet Wire Coil: 1/16” around bowl

Mechanical Design Mechanical Design

Dimensions of Bristol

Neodymium Sphere: 1/2”

6 Layers of 30 Gauge Magnet Wire: 1/16”

6061 Aluminum Torus

○ Outer Diameter: 3”

○ Inner Diameter: 2 1/8”

○ Mounting Fixtures with 0.116” hole: 1/4” x 1/4” x 3/4"

Mechanical Design Mechanical Design

Dimensions of Jerk

1” Outer Diameter x 3/4” Inner Diameter

Height: 4.5”

30 Gauge Magnet Wire Coil: 2” length and 6 layers (at

1/16”)

Mechanical Design Mechanical Design

Dimensions of Elvis

Lavalier Microphone 11.9 mm x 5.3 mm x 2.8 mm

Dimensions of Aubade

Photovoltaic Panel: 2.9” x 3”

Dimensions of Crusher

Piezoelectric Block: 1” x 1” x 1 1/2"

Mechanical Design Overview- Physical Mechanical Design Overview- Physical ModelModel

Design in CanisterDesign in Canister

Right View Left View Front View

PlatesPlates

Bottom Plate

PlatesPlates

Middle Plate

Arduino’s Not Visible

Design DescriptionElectrical

Dylan Stobbe

Electrical Design Electrical Design

De-Scopes

No de-scopes have occurred to date or are currently

planned.

Off Ramps

Change COTS sensing system if availability becomes an

issue.

Use alternative data logging system if OpenLog to Arduino

interfacing becomes impossible.

Subsystem Overview- Block Subsystem Overview- Block DiagramDiagram

Transducers

Resi

sto

r

uController(Master Arduino)

ATMega2560

uController(Slave Arduino)

ATMega2560

I2C

OpenLog(Master)

OpenLog(Slave)

Balloon Board

6vNiMH

Battery

VoltageRegulator6v to 5v

Legend

Data

Power

Schematics for PCB’sSchematics for PCB’s

Electrical Design Electrical Design Major Functions

Transducers supply voltage during flight profile.

Op Amps amplify voltage.

Rectifiers convert AC to DC.

Low pass filters remove high frequency noise.

Resistors allow calculation of power and current.

Arduinos measure scaled voltage.

COTS sensing package provides information on voltage used to allow

comparison of transducer effectiveness.

Open-logs store information from Arduinos and COTS sensing package.

SSystem Level Software Flow ystem Level Software Flow ChartChart

Electrical Design Electrical Design Pseudo Code

Int inputVoltage = 0; //declare variables

Void setup() {

Serial.begin(300);

}

void loop() {

//read voltages

int voltage=analogRead(inputVoltage);

//display voltages in serial monitor

Serial.print(inputVoltage);

}

Design DescriptionTest/Software

John Benfield

Test Design Test Design

De-Scopes & Off Ramps

No de-scopes to date.

Off Ramps:

○ Include using a component rocket only if problems arise with the

full-scale rocket.

○ Using a vibration analysis demonstrator for shake table analog.

Changes Since PDR

Will purchase a kit rather than building a full-scale rocket.

Prototyping & AnalysisNathan Keller

Prototyping & AnalysisPrototyping & Analysis

Arduino Prototyping

Tested Arduino at multiple baud rates with multiple sources

of voltage.

○ Measured Arduino’s own 5v and 3.3v outputs as well as an

external 4.8v NiMH battery.

○ Arduino returned accurate values for each trial.

Prototyping & AnalysisPrototyping & Analysis

Key Results

Accurately read DC voltage from various sources.

Data procured at acceptable baud rates demonstrated that

the Arduino Mega is an acceptable microcontroller.

Prototyping & AnalysisPrototyping & Analysis

Prototypes Completed to Date

4 inch diameter scale rocket

42 inch length

Test Completed to DateTest Completed to Date

Grow-Hot produced voltage.

Aubade produced voltage.

Elvis produced voltage.

Jerk produced voltage.

Testing Completed to DateTesting Completed to DateKey Results

Elvis

○ Produced 0-200 milivolts maximum.

Aubade

○ A single solar cell will produce 0-500 milivolts maximum.

Jerk

○ Produced 0-3.6 volts maximum.

Grow-Hot

○ Produced 0-150 milivolts maximum.

Prototypes Completed to Prototypes Completed to DateDateJerk

Aubade

Grow Hot

Elvis

Prototyping Completed to Prototyping Completed to DateDateKey Results Jerk

○ Completed a nominal design. Bench tested and produced reasonable voltage.

Grow Hot

○ Acquired prototype TEC and determined test methodology with results obtained.

Aubade

○ Acquired multiple solar cells, determined test methodology with results obtained.

Elvis

○ Acquired multiple microphones and tested over a wide range of input frequencies

and amplitudes.

Prototyping & AnalysisPrototyping & Analysis

PEGASIS Mass Budget

Subsystem Total Mass (lb)

BSTL .26 (by hand)

EMPD .08

DVBD .18 (by hand)

JERK .35

CRSH .11

ABDE .02

ELVS .01

Total 1.01

Over/Under (including electrical & hardware)

0.78

Prototyping & AnalysisPrototyping & Analysis

Detailed Power Budget

Subsystem Quantity Voltage (V) Current (A) Time in Use (min)

Amp-Hours

ARD 2 5 0.2 20 0.133

BB 1 3.3 0.03 20 0.010

OL 2 3.3 0.006 20 0.004

OpA 16 0.0015 20 0.008

Total: 0.155 Amp-Hours

Manufacturing PlanMechanical

Gary Staggers

Mechanical Manufacturing Mechanical Manufacturing PlanPlanNeed to be manufactured:

Makrolon Plates

Bowl base of EM Pendulum

Housing of Bristol

Mounting the base of Diving Board

Test canister in plastic

Mechanical Manufacturing Mechanical Manufacturing PlanPlanStill need to be procured:

Neodymium magnets for Diving Board and Bristol

Piezoelectric cantilever beam

4-40 bolts

Photovoltaic panel

Microphone (Elvis)

Angle brackets

Mechanical Manufacturing Mechanical Manufacturing PlanPlan

Manufacturing Plan

1/9: Flights Awarded

1/20: Jerk, Aubade, Grow Hot, Crusher, Elvis procured

1/25: Parts received, ready to assemble EM Pendulum, Bristol and Diving Board

1/30: Online progress report 3 due

2/10: Remaining transducers completed

2/11: Shake table/ spin tests

2/12: Test data analysis

2/13: Individual subsystem test due

Manufacturing PlanElectrical

Dylan Stobbe

Electrical Manufacturing PlanElectrical Manufacturing PlanManufacturing Plan

1/9: Flights Awarded

1/25: Interface Arduinos to OpenLogs; procure remaining electrical system components

1/30: Progress Report Due

2/10: Remaining electrical components completed

2/11: Shake table/ spin tests

2/12: Test data analysis

2/13: Individual subsystem test due

Manufacturing PlanSoftware

Dylan Stobbe

Software Manufacturing PlanSoftware Manufacturing Plan

Discrete Blocks of Code

Arduino to OpenLog interface code.

Explore voltage measuring further.

○ Simultaneous voltage measurements from each transducer

COTS sensing package to slave Arduino interfacing code.

Countdown timer program to run in background.

Software Manufacturing PlanSoftware Manufacturing Plan

Code co-dependencies:

○ The DataLogging blocks of code will be the backbone of the

experiments success, special attention must be paid to this part of the

software.

Create beta version of payload software by mid February to

allow time for reiterations and testing of mechanical

components.

Testing PlanSystem Level

Derek Spencer

Testing PlanTesting Plan Verify payload can withstand high G forces and strong vibrational

forces.

Hardware mounts, electrical connectors, circuit boards and

transducer prototypes will need to remain functional after testing.

Test will include a mock-up payload (containing legacy

equipment) in conjunction with a full-scale rocket measuring 10”

in diameter and 98” long and incorporating a Cesaroni J1520

motor to provide valuable insight into survivability of components

during flight.

Mock-up payloads will be tested on custom-built shake tables

(high & low frequency).

Test RocketTest Rocket

Testing PlanMechanical Level

Derek Spencer

Mechanical Testing PlanMechanical Testing Plan

Tests will be conducted for structural integrity.

Individual components will be tested on a small-scale

rocket and shake tables.

Measurements of G forces and vibrational forces will be

taken to decide if the components retain their functionality

and structure during flight simulation.

Testing PlanElectrical Level

Derek Spencer

Electrical Testing PlanElectrical Testing Plan

Tests to include:

○ Magnetic interference

○ How to shield from interference

○ Shrink wrap and tie durability when under stress and increased

heat

○ Current flow

○ Connections between transducers/sensors and Arduinos

○ Individual components tested on a small-scale rocket & shake

tables

Testing PlanSoftware Level

Derek Spencer

Software Testing PlanSoftware Testing Plan

Testing and debugging will be conducted by the electrical

team in conjunction with electrical systems test.

Testing of software components will be conducted on a

scale rocket flight, shake table, and bench top testing.

Software tests will be incorporated into some of the

mechanical tests to determine compatibility.

Risks

Bradley Hager

Risks Since PDRRisks Since PDRRare Unlikely Possible Likely

Critical BCF.RSKGSM.RSK

Catastrophic RTC.RSKMSD.RSK

RTC.RSK: Rocket CATO

MSD.RSK: MicroSD card fixturing ineffective

BCF.RSK: Battery cell fails(internal

delamination, overcurrent shorts battery,

etc…)

GSM.RSK: G-force issues on surface mount

electronics

Mitigation

Rocket CATO is out of our control

Shake Table Testing of fixturing for MircoSD

Card

Proper testing and ensuring that wiring is

properly grounded

Shake table testing of surface mount

electronics

New RisksNew Risks

Rare Unlikely Possible Likely

Marginal ARF.RSK

Critical

Catastrophic RTC.Risk

RTC.Risk: Rocket CATO

ARF.RSK: Anomalies in rocket flight

UPE.RSK: Unforeseen programming

errors

Mitigation

No mitigation available

Debug and test Arduinos for program

Bench test and testing on full scale rocket

will reveal programming errors

User Guide ComplianceBeau Brinkley

User Guide ComplianceUser Guide Compliance

The mass of the payload, including canister, is 9.218 lbs.

The center of mass of our canister is within the 1”x1”x1”

envelope requirement, verified using Autodesk Inventor.

The payload will be powered by a 7.2 volt NiMH battery.

Design of payload will utilize a 1.SYS.1 activation.

Sharing LogisticsSharing Logistics

PEGASIS will be partnering with the New Jersey Space Grant.

They plan to collect and analyze data for future space research

through various experiments.

Planned communication will take place via teleconferences, Google

Chat & Google Docs along with Vyew.

Pegasis will leave the top plate clear for the New Jersey Space

Grant Team. Allowing for variable capability to move CG and adapt

in z & theta without constraining our partner.

Scheduled teleconference with New Jersey Space Grant December

5th

Project Management Plan

Beau Brinkley

ManagementManagementBudget Overview

ManagementManagementMilestone Schedule

ManagementManagementWork Package Schedule

ManagementManagementTask Schedule

ManagementManagementWork Breakdown StructureWork Breakdown Structure

Project Phase 1 • Timeline 8/15/2011 – 1/9/2012

Project Phase 1 Deliverables• Conceptual Design Review• Preliminary Design Review• Critical Design Review

Conclusion Conclusion Plan of Action

Order any parts that still need to be procured to complete

prototypes.

Finish all prototypes.

Fly scale rocket and record data from flight.

Objects to Finished Before Winter Break

Prototype.

Save test data to open logs.