Mitchell Aerospace and Engineering Mitchell Community College October 26, 2011 Preliminary Design...

Mitchell Aerospace and Engineering Mitchell Community CollegeOctober 26, 2011

Preliminary Design Review

RockSat- C

Mission OverviewMission Overview

System OverviewSystem Overview

Subsystem DesignSubsystem Design

Prototyping PlanPrototyping Plan

Project ManagementProject Management

Outline of Presentation Outline of Presentation

Mission OverviewBeau Brinkley

Mission OverviewMission OverviewGoal Statement:

Our goal is to design and implement various generators to

passively collect energy for possible use by space based

instrumentation. We expect to harvest energy from the flight

of the rocket, solar, magnetic and other sources.

Results may lower cost and power requirements for space

science by reducing the weight of electrical components.

Mission OverviewMission Overview

Theory and Concepts:

Various transducers will generate electrical power utilizing

Electromagnetic, Photoelectric, Seebeck, Peltier, and

Piezoelectric effects.

Total power output from all transducers will be determined

and compared to the power needed to operate and

onboard off-the-shelf space science package.

Previous work includes:

• Electrodynamic tethers tested with the Space Shuttle

• MEMS based micro-engineered motion energy harvesting devices (Imperial College of London, 2007)

• MIDE out of Boston, Ma., founded in 1989, develops vibration energy harvesting devices

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.

Mission OverviewMission Overview

Expected Results

For each transducer, voltage across a known resistor will

be measured and stored.

○ All transducers will require amplification of voltage at some

range.

The power used by the balloon board will be measured and

stored.

Measurable data from the balloon board will be saved.

System OverviewMechanical

Brad Hager

Subsystem DefinitionsSubsystem Definitions

“EM Pendulum” Magnet suspended on a pendulum over a copper coil will use horizontal vibrations and angular velocity

“Aubade” Photovoltaic panel

“Jerk” Magnet surrounded by a copper coil will use vertical vibrations

“Grow-Hot” Peltier thermoelectric cooler will use temperature changes

“Bristol” Magnets in a circular track will use angular velocity

“Crusher” Piezoelectric block will use vertical g-forces

“Elvis” Electromagnetic microphone will use sound vibrations

“Diving Board” Piezoelectric cantilever will use horizontal vibrations

Subsystem Overview- Physical Subsystem Overview- Physical ModelModel

Design in CanisterDesign in Canister

Right View Left View Front View

Critical InterfacesCritical InterfacesInterface Name Brief Description Potential Solution

BSTL/STR Will mount on top of the 2nd plate *All mounting of transducers will be directly into Makrolon and designed to withstand appropriate Gee forces.

Bristol will be mounted using 3/4” 4-40 CSK bolts; located 1/2” from center

EMPD/STR Two separate assemblies: Bowl will mount to the bottom plate; pendulum to the bottom of the 2nd plate .

Pendulum mounted beneath 2nd plate using 1/2”4-40 CSK bolts, and 3/8” 4-40 CSK bolts for the bowl

DVBD/ STR Tabs will be mounted directly to bottom plate and the transducer suspended vertically.

Support tabs integrated into design and mounted using 3/8” 4-40 bolts

JERK/STR Will span the entire z-axis of the payload; mounted directly to bottom and top plates

Support tabs integrated into design and mounted using 3/8” 4-40 bolts

CRSH/STR Piezoelectric plate actuators will be stacked vertically and constrained between two mounting brackets on the bottom and 2nd plate.

Mounting brackets made of 6160 aluminum and mounted using 3/8” 4-40 bolts.

Critical InterfacesCritical InterfacesInterface Name Brief Description Potential Solution

ABDE/STR Positioned facing the optical port: mounted on the bottom plate and option for bottom of 2nd plate

Mounting options still to be defined before CDR

ELVS/STR Mounted on the top of the 2nd plate Mounting options still to be defined before CDR

Transducers/ Arduinos

Each transducer is connected to two analog inputs on the Master Arduino. Current runs through a series of op amps, low pass filters, and is then a known resistor; where voltage is measured. Power output will be calculated after rocket flight.

Use right angle Molex connectors from resistor inputs to insure clearance between Arduino and top plate.

SSystem Level Block Diagramystem Level Block Diagram

System OverviewElectrical

Nathan Keller

Subsystem DefinitionsSubsystem Definitions

Electrical is broken down into three

subsystems:

Power

Energy Harvesting & Measurement

Data Sensing

System Overview-Block DiagramSystem Overview-Block Diagram

Transducers

Resis

tor

uController(Master Arduino)

ATMega2560

uController(Slave Arduino)

ATMega2560

I2C

OpenLog(Master)

OpenLog(Slave)

Balloon Board

6vNiMH

Battery

VoltageRegulator6v to 5v

Legend

Data

Power

Subsystem Overview- Physical Subsystem Overview- Physical ModelModel

Arduino Microcontroller

High Altitude Sensing Board

OpenLog

System Overview- Physical ModelSystem Overview- Physical Model

Critical InterfacesCritical InterfacesInterface Name Brief Description Potential Solution

I2C Inter-Integrated Circuit used to allow communication between a master and slave, or multiple slave, microcontrollers.

Interface uses serial data to communicate between Arduino’s allowing the master to control the slave.

Op Amps Output voltage is linearly proportional to the difference between inputs by the factor of the gain.

Input signal range is amplified from millivolt to zero to five volts.

Transducers to Arduinos

Each transducer is connected to two analog inputs on the Master Arduino. Current runs through a series of op amps, low pass filters, and is then a known resistor; where voltage is measured. Power output will be calculated after rocket flight.

Use right angle Molex connectors from resistor inputs to insure clearance between Arduino and top plate.

SSystem Level Software Flow ystem Level Software Flow ChartChart

Ready Mode

G-SwitchActivation(indicatesLaunch)

Balloon BoardStarts

analogRead()while loop

starts

Voltageoutput fromgenerators

Data FromBalloonBoard

CountdownTimer Starts

Countdownreaches 0

Int valuesfrom

analogRead()

Data Logger

Data tomicroSD

card

Shutdown

Data Logger

Data tomicroSD

card

System OverviewProject Level

Samuel Fox & Joseph Edwards

Requirement Verification Requirement Verification PlanPlan

Weight required for both electronic and mechanical

systems will be determined. Combined canister weight will

be less than the maximum requirement of 20 + 0.2 lbs .

Center of mass will meet requirements of the RockSat-C

Users Guide and not negatively effect partnered payload.

Mock up canister will meet specified requirements set by

the RockSat-C Users Guide for accurate payload

simulation.

Potential difference between plates will be zero. All plates

will be electrically connected to a common ground.

User Guide ComplianceUser Guide Compliance

Mitchell’s project will use the 1.SYS.1 payload activation

scheme, allowing us to receive power before G-switch

activation.

All wires will be tied and staked to prevent disconnects

during flight.

Sharing LogisticsSharing Logistics

Pegasis will be partnering with the New Jersey Space

Grant.

Planned communication will take place via

teleconferences, Google Chat & Google Docs along

with Skype.

Pegasis will leave the top plate clear for the New

Jersey Space Grant Team. Our design has the

capability to move CG in z & theta without

constraining our partner.

Subsystem DesignMechanical

Gary Staggers

Bristol Transducer HousingBristol Transducer Housing

Jerk TransducerJerk Transducer

PerspexTube

Neodymium Magnet

Aubade (Solar) TransducerAubade (Solar) Transducer Electrodes

Solar Panel

Diving Board TransducerDiving Board Transducer

Neodymium Magnets

PiezoelectricPlate Actuator

EM Pendulum TransducerEM Pendulum Transducer

Magnetic Pendulum

Wire-wrappedBowl

Elvis TransducerElvis Transducer

Microphone

Base

Grow Hot (TEC) TransducerGrow Hot (TEC) Transducer

Electrodes

ThermoelectricCooler

Crusher (Piezo) TransducerCrusher (Piezo) Transducer

Electrodes

PiezoelectricPlates

Key Trade StudiesKey Trade Studies

Piezoelectric Plate Boston Piezo-Optics Noliac

Cost 8.5 6

Availability 10 10

Coating 9.5 8

Total Time to Customer

8 6

Made to order 10 9

Average 9.2 7.8

Key Trade StudiesKey Trade Studies

Permanent Magnets Neodymium Iron Boron (NdFeB)

Samarium Cobalt (SmCo)

Cost 6 8

Availability 10 5.5

Flux Density 10 8.2

Demagnetization (Oersted)

10 7.5

Max Power (BH) 10 6.5

Max Temperature (C) 7.5 10

Curie Temperature (C) 7 10

Average 8.6 8.0

http://www.coolmagnetman.com/magtypes.htm

Key Trade StudiesKey Trade Studies

Plate Material Aluminum 6061 Makrolon

Cost 10 5.7

Availability 10 9

Density 4.4 10

Machinability 7.5 10

Tensile Strength (Mpa)

10 6

Electrical Insulation 0 10

Average 7 8.5

Subsystem Risk Matrix Subsystem Risk Matrix Rare Unlikely Possible Likely

Negligible TFC.RSK

Marginal ARF.RSK

Critical TFI.RSKMPI.RSKCNI.RSK

Catastrophic RTC.RSK

TFI.RSK: Transducer fixture issues

TFC.RSK: Transducer functionality changes due to Gee-forces in flight

MPI.RSK: Makrolon plate integrity

CNI.RSK: Canister integrity

ARF.RSK: Anomalies in rocket flight

RTC.RSK: Rocket CATO

Subsystem DesignElectrical Dylan Stobbe

Subsystem Subsystem Block Diagram – Block Diagram – PowerPower

6v 1600 mAh batterypack.

(Tenergy : side by sidecells)

6v to 5vVoltage

Regulator

Arduino MasterATmega2560

Arduino SlaveATmega2560

Balloon BoardSpark Fun HighAltitude Sensing

Board

OpenLog Openlog

Key Trade Studies – Key Trade Studies – PowerPower

Battery 6v Tenergy 1600 mAh NiMH

Tenergy 7.2v 3800 mAh NiMH

Cost 8 9

Availability 10 10

Capacity 8 10

Voltage 9 7

Weight 9 8

Average 8.8 8.8

Subsystem Subsystem Block Diagram – Block Diagram – MicrocontrollerMicrocontroller

Arduino MasterATmega 2560

Arduino SlaveATmega 2560

OpenLog OpenLog

SerialData

SerialData

Transducers

Each Generator uses 2analog inputs on mastermicrocontroller

Sparkfun HighAltitude Sensing

Board

Sensing Boardsends serial datainto slave Arduino

I2C

Digital Pins four and five onboth Arduinos are used to createand open line of communicationbetween microcontrollers

Key Trade Studies –Key Trade Studies –MicrocontrollerMicrocontroller

uController ATMega2560 Rabbit BL4S100

Cost 10 5

Availability 10 6

Clock Speed 8 10

AD Convertors 9 9

Programming Language

9 9

Average 8.6 7.8

Subsystem Subsystem Block Diagram – Block Diagram – Data SensingData Sensing

Arduino SlaveATmega 2560

OpenLog

SerialData

Sparkfun HighAltitude Sensing

Board

Sensing Boardsends serial datainto slave Arduino.

Key Trade Studies – Key Trade Studies – Data SensingData SensingData Sensing Sparkfun High

Altitude Sensing Board

DIY Printed Circuit Boards

Cost 10 7

Availability 10 7

Capabilities 10 10

Expandability 8 10

Structural Integrity 7 10

Average 9 8.8

Risk Matrix Risk Matrix Rare Unlikely Possible Likely

Negligible

Marginal CRA.RSK VCL.RSK

Critical CSF.RSK EOH.RSKUPE.RSK

GSM.RSKBCF.RSK

Catastrophic MSD.RSK

GSM.RSK: G-force issues on surface mount electronics.BCF.RSK: Battery cell fails(internal delamination, overcurrent shorts battery, etc…)VCL.RSK: Vibration causing loose connections.CRA.RSK: Cosmic rays affect electronic components in random matters.EOH.RSK: Excess heat causing electronics to malfunction. UPE.RSK: Unforeseen programming errors. MSD.RSK: MicroSD card fixturing ineffective.CSF.RSK: Canister seal failure.

SafetySam Fox

Goal StatementGoal Statement

Our team will pay acute attention to detail and complete an

honest assessment of risks, failures and hazards associated

with this project. The whole team will be educated on all

safety precautions and must pass a safety test before

assembly and testing begins.

Safety Risk ManagementSafety Risk Management

Hazard Effect of Hazard Mitigation

Chemicals in paint, solvent, adhesive Possible respiratory and skin irritation

Take precautions and wear gloves, safety glasses and have good ventilation

Ignition of pyrotechnic compounds Fire, damage to equipment, personal injury

Follow safety rules; wear cotton clothing and do not smoke or have other static producing items in the area

Use of power tools Cuts or other injuries, damage to equipment, flying debris

Follow manufacturer’s safety instructions; wear safety goggles and do not operate without supervision

Misfire on launch pad Rocket may not be safe to approach Write procedures to plan for this contingency and follow NAR and TRA safety rules

Prototyping PlanMechanical

Samuel Fox

ChartChart

Prototyping PlanElectrical

ChartChart

Prototyping PlanTest

ChartChart

Component Rocket Schematic

Length: 46.50 inches Diameter: 4 inch payload to a 3 inch body tube

Mass: 3.3 lbs Max Altitude: 2000 ft

Project Management PlanBeau Brinkley

All project management documents are large working files therefore, are viewed as screenshots in this presentation. Actual documents may be viewed outside of this construct.

Mission OverviewMission Overview

Organizational Chart

Mechanical Team MembersMechanical Team Members

Brad Hager, 22 ArchitectureUNC Charlotte

Michael Brown, 20Mechanical EngineeringUNC Charlotte

John Benfield, 20Biology, Psychology, Psych/NeuroTBD

Gary Staggers, 31 Mechanical EngineeringUNC Charlotte

Electrical Team MembersElectrical Team Members

Dylan Stobbe, 21Computer EngineeringUNC Charlotte

Ryan Howard, 22 Associate of Science Degree Air Force

Nathan Keller, 17Associate of Science Degree

Test Team MembersTest Team Members

Samuel Fox, 20Chemical EngineeringNC State

Derek Spencer, 34Biology, Pre-MedUNC Charlotte

Joseph Edwards, 40 Mechanical Engineering TechnologyUNC Charlotte

Project Manager & Safety Project Manager & Safety Officer Officer

Beau Brinkley, 22Systems EngineeringUNC Charlotte

Erin Wilson, 25 Veterinary SchoolNC State

Team Members & Contact Information:

Name E-Mail Phone Contact

Erin Wilson erwilson28244@mitchellccmail.com 704-657-3866

Brad Hager bwhager@mitchellccmail.com 704-500-9508

Michael Brown mdbrown1819@mitchellccmail.com 704-497-4225

John Benfield jbenfield@mitchellccmail.com 704-775-5530

Beau Brinkley bhbrinkley@mitchellccmail.com 704-902-0627

Nathan Keller nlkeller@mitchellccmail.com 704-872-2323

Samuel Fox sjfox@mitchellccmail.com 704-928-5172

Derek Spencer dpspencer@mitchellccmail.com 704-883-4731

Dylan Stobbe drstobbe@gmail.com 828-278-9466

Ryan Howard ryo242@gmail.com 704-663-2299

Joseph Edwards jdedwards925@mitchellccmail.com 704-500-4003

Gary Staggers garystaggers@gmail.com 704-778-0588

ManagementManagement

Test Total:$1411.50

Electrical Total:$441.25

Mechanical Total:$251.50

Total Available Funds:$5604.25

Budget Overview

Travel Total:$3500.00

ManagementManagementSchedule

Schedule Milestones

• Project Charter Introduced 8/29/2011

• Project Scope Defined9/19/2011

• Conceptual Design Review 10/3/2011

• Preliminary Design Review Progress Report10/17/2011

• Preliminary Design Review10/26/2011

• Critical Design Review Progress Report11/14/2011

Critical Design Review11/30/2011

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

ConclusionConclusionGoing Forward

• Mechanical• Mechanical component procurement.• Construct Prototype designs and begin 3d printing of part models.

• Electrical• Testing of the Arduinos, writing and debugging code for component test flights. • Test voltage readings from the Arduinos with known voltages to confirm accuracy and resolution.• Interface with Mechanical regarding initial wiring paths.

• Test • Begin construction of shake table and other testing equipment. • Construct component Test Rocket flights for equipment performance results.

• Project Management• Updates to project schedule and budget estimates as compared with actuals.• Plan control contingencies and risk mitigation. • Safety program implementation with hardware construction. • Begin interfacing with New Jersey regarding payload requirements.

Conclusion Conclusion

How much flight hardware needs to be built by CDR?

Data concerning sounding rocket vibration frequencies and

amplitude?

Expectations from CDR to down select in January?

Questions