Advisors: Dr. John Helferty & Dr. Chang-Hee Won

Temple University Advisors: Dr. John Helferty & Dr. Chang-Hee Won

Charles Wright Jinyan Chen

Billy Cheng Brittany Gray

1

Objectives  Design, Build, And Test A

Vibration Suppression System To Counteract Launch Vehicle Vibrations

 Measure The Vibration Environment Inside The Terrier-Orion Rocket   Will Use Two Identical Vibration

Measurement Systems ○  A Custom Built Passive Damping

System ○  Rigidly Attached System

2

Goals

 Dampen The Magnitude Of The Vibrations By A Magnitude Of 5 To 1  Measurements Will Be Compared From

Damped To Undamped System After Flight

3

Benefits

 Efficient Vibration Isolation Systems For Small Payloads   Increased Operational Performance Of

Onboard Sensing Equipment  Better Protection Of The Sensing

Equipment

4

Related Experiments

 Paper by D.I. Carantu and C. Shove Titled “Overview of Payload Vibration Isolation Systems”   Tested Vibrations On Small Sounding

Rockets   They Were Able To Find The Following ○  Most Passive Vibration Systems Do Not

Achieve Greater Than A 5 to 1 Ratio ○  Passive-Active Vibration Systems

Achieved A 10 To 1 Ratio

5

Concept Of Operations

Rocket Launch

G-Switch Activated

RBF Wires Connected

Accelerometers (x,y,z)

Activated

AVR Activated

Flash Memory

Activated

Level Translator Activated

Rocket Splash

Payload Retrieval

System Deactivated

6

Expected Results

 Achieve A Passive Damping System With 5 to 1 Damping Ratio  Ratio Refers To The Magnitude Of

Vibration  Data Logging For Entire Flight  Sufficient Power For Entire Flight

7

Functional Requirements Requirement Method Status

The payload must not exceed ~6.5bs (~2.94kg). Design

Two (2) 9-Volt batteries will supply power to each system. Design, Test

The payloads’ center of gravity (CG) shall be within 1 cubic inch of the canister’s centroid.

Design, Test

The allowable static envelope of the payload is cylindrical with a diameter of 9.3” (cm) and a height of 4.7” (cm).

Design

The payload must interface to the ten (10) bulk head screw. Design

The payload must have no input power (no-volts) prior to launch. Design, Test

The payload must withstand temperatures up to 100F. Analysis, Test

The payload must withstand forces up to 25Gs. Analysis, Test

The payload electronics must be properly harnessed and staked. Design

The payload must pass the DITL test. Design, Test

The payload must be capable of meeting all mission objectives. Design, Test

8

Compliant

Partially Compliant

Functional Block Diagram 9V Li Ion Batteries

RBF Wiring

G-Switch

Voltage Regulator

3.3V 5V

Flash memory

ADC Data

Microprocessor

XL, YL, XH, YH, ZL, ZH Accelerometers

Data out

Vcc VL

Logic Level Translation Data

In

ISP (Data

retrieve)

Level Shifter

Data Analysis

Coding Micro

PC ISP

(Programming code )

9V 5V 3.3V Data

Legend

9

Structural Drawings

10

 Plate Mounting Inside Canister

Expanded View Of Plates Passively Damped System

Rigidly Mounted System

Structural Drawings

 Plate Details

11

Gel Mounts

Springs

G-Switch

G-Switch

9 V Batteries

9 V Batteries

Main Board

Main Board Z Accelerometers

Z Accelerometers

RockSat Canister

Shared Can Logistics Plan

 Canister Being Shared With West Virginia University And Louisiana University  Communications Through Email And

Teleconference  We Will Occupy The Top Half Of The

Canister  All Structural Diagrams Will Be

Drawn On Solid Works  Allows For Center Of Gravity Simulation

12

System Schematics

13

Subsystem Requirements

 Structure  Vibration Isolation System  Power  Mass  Sensors And PCBs  Command And Data Handling  States

14


 Structure   Two Plates Containing Identical

Electronic Equipment On Each   Integrate Into Canister Using Support

Brackets From RockOn Workshop

15


 Structure   Preliminary Setup

Of Board Without Vibration Isolation System

16


 Vibration Isolation System   Passive Isolation System  Maximum Vibration Isolation Ratio

Desired   Selection Between Three Designs To Be

Decided Upon After Shock And Vibration Testing On Shaker Tables

17

Design Concept 1

18

 Silicone Gel Mounts  Designed For

Isolating Printed Circuit Boards

 Offers Shock And Vibration Damping

Design Concept 2

19

 Spring Damping System o  Board Will Be

Suspended Between Springs To Dampen Motion In All Directions

Casing

Springs Printed Circuit Board

20

Design Concept 3  Hybrid-

Spring & Gel Mounts   The PCB Is

Mounted On A Hexagonal Plate With The Gel Mounts And Springs Integrated

Gel mounts Top view

Side view

Springs PCB

Casing


 Power (For Each Identical System)  Two 9V Lithium Ion Batteries

Connected In Parallel  Provides Continuous Power

Throughout Entire Flight  Voltage Regulators Will Step

Voltage Down To 5 And 3.3V

21

Subsystem Requirements   Power For Each Identical System

Major Power Consumption Parts Voltage (V)

Current (mA) Power

AVR Microcontroller 3.3 12 39.6mW Low Range X & Y Axis Accelerometer 5 1.1 5.5mW Low Range Z-axis Accelerometer 5 1.1 5.5mW High Range X &Y Axis Accelerometer 5 2.9 14.5mW High Range Z-axis Accelerometer 5 2 10mW Flash Memory 3.3 20 66mW Logic Voltage Shifter (VL side) 3.3 0.13 0.429mW Logic Voltage Shifter (Vcc side) 5 0.016 0.08mW

Total Power Consumed 141.61 mW Total Energy Requirement (Entire Flight Takes About 25mins) 211.5 J

Power That Batteries Are Able To Supply (Able To Supply More Than 1 Hour)

270mW

22

Subsystem Requirements  Mass

Part Mass (lbm) QTY Total Mass (lbm)

3/16’’ Polycarbonate Plates 0.550 2 1.100 Spacing Standoff (0.25’’) 0.004 5 0.020 Female-Male Standoff (1.5”) 0.015 20 0.300 Two 9V Batteries With Bracket 0.180 2 0.360 G-switch 0.010 2 0.010 PCB With Components Assembled (Est.)

0.200 2 0.400

Silicone Gel Mount (Est.) 0.010 8 0.080 Springs (Est.) 0.005 10 0.050 Plate Used To Attach Spring System (Est.)

0.200 1 0.200

Total Mass Of Designed System (lbm) 2.52

23


 Sensors   Two Identical Vibration Measurement

Systems ○  Dual Axis, Low And High Precision

Accelerometers For X And Y Direction ○  Single Axis, Low And High Precision

Accelerometers For Z Direction

24

Sensor Specs  X & Y Axis Accelerometer (5mm X 5mm X

2mm)   High g ○  AD22284-A-R2CT-ND ○  It Is A Dual Axis Accelerometer Available In +/-

35 g Output Full-scale Ranges ○  Accuracy: 0.2% Of Full Scale

  Low g ○  ADXL203 ○  It Is A Dual Axis High Sensitive Accelerometer

Available In +/-1.7 g Output Full-scale Ranges ○  Resolution: 1 mg At 60Hz

25

Sensor Specs

 Z Axis Accelerometer (5mm X 5mm X 2mm)  High g ○  AD22279-A-R2CT-ND ○  It Is A Single Axis Accelerometer Available In +/-

35g Full-scale Ranges ○  Accuracy: 0.2% Of Full Scale

  Low g ○  ADXL103CE ○  It Is A Single Axis High Sensitive Accelerometer

Available In +/-1.7g Full-scale Ranges ○  Resolution: 1mg At 60Hz

26


 Command And Data Handling  Will Utilize Onboard Flash Memory For

Data Storage  Microprocessor Will Utilize C

Programming To Handle Data  Code Must Accommodate Complete

Data Flow For Entire Flight  Adapted From RockOn Workshop

27

Command And Data Handling

 Rough Outline Of Code Flow

Initialize Systems

• Initialize ADC • Initialize Flash Memory • Initialize Timer

Check Board Connectivity

• Check Microprocessor Connection

Write Sensor Data

• Write Converted Data To Flash Memory

Sample Sensors

• Wait For Analog Data From Sensors • Convert To Digital Data

28

Data Storage Overview

29

Analog Data (Sensors)

Data Flash 16Mbits =

2MB

ADC

Microprocessor

Memory Buffer

Write

Memory Dump (PC)

Memory Flush

States

 Prior To Rocket Launch, System Will Be Idle

 Upon Rocket Launch, The G-switch Will Activate The System And System Will Be Active For Entire Flight

30

Parts List

31

Parts Manufacturer Model No. Quantity AVR Microcontroller Atmel ATMega32-16PU 2 9V Flight Battery(Lithium)

Ultralife U9VL-J 4

Low range Accelerometer(x,y)

Analog Devices ADXL203CE 4

Low range Accelerometer (Z)

Analog Devices ADXL103CE 2

High range Accelerometer(x,y)

Analog Devices AD22284-A-R2CT-ND 4

High range Accelerometer(z)

Analog Devices AD22279-A-R2CT-ND 2

Flash Memory Altmel AT26DF161A 2 G-Switch Digikey SW156-ND 2 5V Voltage Regulator Texas Instruments LM2937IMP-5.0CT-ND 2

3.3 V voltage Regulator

Texas Instruments LM2937IMP-3.3CT-ND 2

RockSat Canister Compliance Type of Restriction Restriction Status

Mass allotment: Half the canister ~ 6.5bs (~2.94kg).

Volume allotment: Half the canister diameter of 9.3” and a height of 4.7”

The payload’s center of gravity (CG): 1”X1”X1” envelope of centroid

Wallops No-Volt Requirement Compliance: RBF wires and G-Switch

Yes

Structure mounts: five (5) bottom bulkheads and five (5) top bulkheads

Top and bottom bulkheads. No mounts

to sides of cans.

Sharing: West Virginia and Louisiana Top Half

32

Compliant

Partially Compliant

33

Design And Testing Process Design Sensing Circuits

• Schematic • Coding • Placement On Plate

Acquire Materials (Sensing Circuits)

• Accelerometers, Microprocessors, Flash Memory, Etc.

Assemble Design

• Sensing Circuitry With Passive System

Design Passive System

• Concept 1 • Concept 2 • Concept 3

Test Design

• Meets Specifications And Requirements • Vibration Damping • Data Acquisition

Acquire Materials (Passive System)

• Silicone Gel Mounts • Springs

Results

• Memory dump • Quantify

Test Other Concepts And Compare Performances

33

Test Plans   Vibrations

  Test Vibration Damping Designs Using In-House Shaker Tables (3 Design Concepts)

  Coding   Withstand Vibration Environment   Verify Programming Codes   Verify Accurate Data Acquisition After

Exposure To Shaker Table ○  Compare Data Of Undamped Board Vs.

Damped Board

34

Test Plans   Heat Test

  Payload Must Withstand ~100 ° F   Circuitry

  Test RBF Wires And G-Switch   Multimeter ○  Verify Power Levels ○  Continuity ○  Verify System Compatibility

  Center of Gravity   Within Specified Region

35

Potential Failure

 Unhooked Spring(s)  Loose Wiring  Loss Of Data Acquisition During

Launch

36

Safety Update

 Meet Requirements Of RockSat Payload Canister User’s Guide   Ensure RBF Compliance ○  RBF Compliance Has Been Implemented In

Schematics ○  G-Switch Activation Has Been

Implemented In Schematics   Ensure CG Compliance ○  Working With The Universities Within Our

Canister To Ensure 1x1x1 in. CG

37

Timeline

38

RockSat 2010 Task/Item

11/1

3

11/2

0

1/22

1/29

2/5

2/12

2/19

2/26

3/5

3/12

3/19

3/26

4/2

4/9

4/16

4/23

4/30

5/7

5/14

5/21

5/28

6/4

6/11

6/18

6/25

CDR Due CDR Teleconference Subsystem Testing

Damping Systems Testing

Subsystem Report Due

Subsystem Teleconference

Subsystem And Damping System Assembly

Subsystem Integration And Testing Report Due

Subsystem Integration And Testing Teleconference

Prepare Full Mission Simulation

Weekly Teleconference First Mission Simulation Report

Due Weekly Teleconference Weekly Teleconference Weekly Teleconference Weekly Teleconference

Second Mission Simulation Report Due

Weekly Teleconference Launch Readiness

Teleconference Weekly Teleconference Integration At Wallops

Launch

Management

39

Part Cost Half Of Canister $7000

Accelerometers (x8) $80

Microprocessor $80

Gel Mounts $150

Springs TBD PCB TBD

Total Cost Approx. $7700

 Budget

Conclusion

  Issues Or Concerns   Structural Interfacing With Other

Universities In Canister

40

Thank you

Questions?

41

Backup Slides

42

Payload Design Requirements

Altitude ≈ 115 km

Spin Rate ≈ 1.3 Hz at Terrier Burnout ≈ 4.8 Hz at Orion Burnout

Max Gravity 25 G With Possible Impulses at 50 G In Z-Axis +/- 10 G in X & Y Direction

Dimensions Diameter = 9.3 Inches Height = 4.75 Inches (Our Half) Center of Gravity = 1 Cubic Inch of Canister’s Centroid

Mass Canister + Payload = 9.07 kg ≈ 20 lbs.

43

Expect To Learn

 Discover If Our Passive System Can Dampen The Canister Vibrations  We Will Compare The Data Between

All The Accelerometers And Gyros

44

Documents

Advisors: Dr. John Helferty & Dr. Chang-Hee Won