High Altitude Balloon Payload Design Project Summer 2012

High Altitude Balloon Payload Design Project

Summer 2012

Design Team:Jen Hoff (EE)Kate Ferris (EE)Alison Figueira (CS)Makenzie Guyer (CS)Kaysha Young (ME/MET)Emily Bishop (ME)

Advisors:Dr. Brock J. LaMeres -Electrical & Computer EngineeringDr. Angela Des Jardins -Montana Space Grant ConsortiumHunter Lloyd -Computer ScienceRobb Larson -Mechanical & Industrial Engineering

Sponsor:NASA

To collect measurements at high altitudes of

atmospheric temperature and

pressure, the internal temperature and

dynamic movement of a payload that meets HASP

flight requirements.

Mission Objective

Budget: $500Schedule: 8 Weeks6/4/12 -7/27/12

Functional RequirementsLog/Store data from the sensors on a non-viotile storage devicePower Sensors and any electronics needed to run these sensorsProtect the system from environmental conditionsProtected from the impact upon landing/jerk from the balloon popProvide state of health information of the system

Performance RequirementsConsume 7 watts in order to accurately represent the research team’s thermal outputLog data from the temperature and pressure sensors at a rate of 1 measurement per secondLog data from the accelerometers at a rate of 3 measurements per secondProvide insulation to keep the internal temperature between -40 C and 60CMust provide at least 4 hours of power for the duration of the setup, flight, and recovery time.Must withstand an vertical force of 10 G and a horizontal force of 5 G

Physical RequirementsMust weight 1.62 kgMaximum Total Volume: 15 cm x 15 cm x 30 cmMust mechanically interface with the HASP payload plate in addition to the BOREALIS system

Reliability RequirementsMust be able to survive preliminary tests and two launches

Mission Requirements

2012 Payload

Computer System Electrical System Mechanical System

System Architecture

Computer System

Computer System

Logging Data Interpreting Data Reading from Sensors

SD Card SD Shield

2012 Payload

Computer System

Electrical System

Mechanical System

Computer Design Specifications

• Interpreting Data– Must be able to retrieve and store sensor data for 4 hours– Temperature data must be retrieved and logged every second– Pressure data must be retrieved and logged every second– Accelerometer data must be retrieved and logged 3 times every

second– Gyroscope data must be retrieved and logged 3 times every

second • Logging Data

– SD Card» Must operate between -40C and 60C» Must have enough storage for data» Must be compatible with SD Shield

– SD Shield» Must operate between -40C and 60C» Must be compatible with computer board» Should have a Real Time Clock

• Reading from Sensors– Must have enough I/O pins for sensors– Must operate between -40C and 60C

• Concept:– Interpreting Data &

Reading from Sensors:• Computer

Board– Logging Data:

• SD Card• SD Shield

Computer Boards

• Choice 1:– Arduino Mega 2560• Price: $54.95• Digital I/O: 54 pins• Analog I/O: 17 pins• Clock Speed: 16MHz• SRAM: 8KB• Flash: 256KB• Dimensions: 4” x 2.1”

Computer Boards (Cont.)

• Choice 2:– Arduino Uno• Price: $29.95• Digital I/O: 14• Analog I/O: 6• Clock Speed: 16MHz• SRAM: 2KB• Flash: 32 KB• Dimensions: 2.7” x

2.1”

Computer Boards (Cont.)

• Choice 3:– Orangutan SVP-1284• Price: $99.95• GPIO: 21• SRAM: 2KB• Dimension: 3.7” x 2.2”

Computer Board Decision

Computer BoardsUnit Cost Weight/Size Language Support I/O TotalImportance 3 3 5 5 4Arduino Mega 2560 R3 Rating 5 4 9 9 6

Factor 15 12 45 45 24 126Arduino Uno Rating 7 7 9 9 9

Factor 21 21 45 45 36 147Orangutan SVP-1284 Rating 3 7 5 6 7

Factor 9 21 25 30 28 104

SD Shields

• Choice 1:– Adafruit Data Logging

Shield for Arduino• Price: $19.50• Dimensions: 2.7” x 2”• Additional: Real Time

Clock

SD Shields (cont.)

• Choice 2:– Seeed Studio SD

Shield• Price: $13.90• Dimensions: 2.25” x

1.8”• Additional: SDHC

support

SD Shields (cont.)

• Choice 3:– Your Duino SD Shield• Price: $8.50• Dimensions: • Additional: Works

with Arduino Uno

SD Shield Decision

SD Card ShieldsUnit Cost Weight/Size Support Compatibility Clock TotalImportance 3 3 5 5 4Adafruit Data Logger Rating 3 5 8 8 10

Factor 9 15 40 40 40 144Seeed Studio SD Shield Rating 5 6 4 7 0

Factor 15 18 20 35 0 88Your Duino SD Shield Rating 7 6 4 7 0

Factor 21 18 20 35 0 94

SD Card Storage

• Pressure:– Example Line: “2012/6/6 13:30:25,10”– 20 characters + ‘\0’ + ‘\n’= 22B per line– Every Second, 14,400s (4hr) = 14,400 lines per file– 316,800B per file– 2 trips = 633,600B for 2 files

• Temperature:– Same as Pressure, 2 sensors = 1,267,200B for 4 files

• Accelerometer:– Example Line: “2012/6/6 13:30:25,10,10,10”– 26 characters + ‘\0’ + ‘\n’= 28B per line– 3 times every second, 14,400s (4hr) = 43,200 lines per file– 1,209,600B per file– 2 trips = 2,419,200B for 2 files

• Gyroscope:– Example Line: “2012/6/6 13:30:25,10,10,10,10”– 29 characters + ‘\0’ + ‘\n’= 31B per line– 3 times every second, 14,400s (4hr) = 43,200 lines per file– 1,339,200B per file– 2 trips = 2,678,400B for 2 files

6,998,400B = 6.67419434MBSo the smaller SD cards

(200MB to 500MB) should have enough storage.

SD Storage SizeSensorPressure 633600Temperature 1267200Accelerometer 2419200Gyroscope 2678400Total 6998400

SD cards

• Choice 1:– Themis Series• Prices: $26 to $62• Storage: 128MG to

2GB• Write Speed:

17.21MB/s• Access Time: 1ms

SD cards (cont.)

• Choice 2:– Delkin Devices• Prices: $21.95 to

$45.57• Storage: 512MB to

2GB• Write Speed: Not

listed, probably ~17MB/s

SD cards (cont.)

• Choice 3:– Sea Level• Price: $34.95• Storage: 1GB• Write Speed: Not

listed, probably ~17MB/s

SD Card Decision

SD CardsUnit Cost Storage Reliability Availability TotalImportance 3 7 8 9Themis Series Rating 5 9 4 2

Factor 15 63 32 18 128Delkin Devices Rating 6 9 5 5

Factor 18 63 40 45 166Sea Level Rating 3 9 5 5

Factor 9 63 40 45 157

Final Decision

• Computer Board: Arduino Uno• SD Shield: Adafruit Data Logger• SD card: Delkin Devices SD card

Design Start

Setup: Define Sensors, start RTC and timers

Loop: Update Timers

A Timer goes off

Retrieve Pressure Data

Interpret Data

Store in RAM

Store on SD card, with timestamp

Back to main program

Event

Temperature

Accelerometer

Gyroscope

Functions follow same format as Pressure

Testing

• Test 1:– Connecting sensors to

board– Reading from sensors and

interpreting data into a useful format

• Test 2:– Creating a timer for each

sensor, testing efficiency– Test the Real Time Clock on

SD shield– Test writing to the SD card

• Test 3:– Testing each sensor

individually with writing to the SD card

– Testing each sensor individually with the timer and writing to SD card.

• Test 4:– Testing all sensors and

timers with writing to SD card.

Budget

Material Cost Shipping Total

Arduino Uno R3 $29.95 $13.25 $43.20

Adafruit Data Logger $19.50 $0.00 $19.50

Industrial SD Card $0.00 $0.00 $0.00

Total $62.70

Electrical System

SensorsPower System

Batteries

PressureTemperature

Movement Acceleration

Interfacing

Electrical System2012

Payload

Computer System

Electrical System

Mechanical System

External Temperature Sensor

SpecificationsMust be able to operate and measure

between -55C and 60CMust be able to read from the sensor

every second Decision Points

Temperature RangeAccuracyCost

MAX6605Price: $0.96Range: -55 to 125degCTemp. Error: +/- 5.8degCSupply Voltage: 2.7V to 5.5VSupply Current: 4.5 uA


Choice #1

TMP124Price: $1.62Range: -40 to 125degCTemp. Error: +/- 1.5degCSupply Voltage: -.3V to 7VSupply Current: 10mA

Choice #2


DS18S20Price: $5.19Range: -55 to 125degCTemp. Error: +/- 2degCSupply Voltage: 3V to 5.5VActive Current: 1mA to 1.5mA

Choice #3


Final Selection: DS18S20 Temperature Sensor

External Temp. Sensors

Function Units Temp. Range Accuracy Cost Total

Importance 5 5 4

MAX6605 Rating 9 3 9 21Factor 45 15 36 96

TMP124 Rating 2 9 9 20Factor 10 45 36 91

DS1820 Rating 9 9 7 25Factor 45 45 28 118

External Temperature Sensor Decision Matrix

Internal Temperature Sensor

SpecificationsMust be able to measure in the range of

-40C to 60CMust be able to read from the sensor

every second

Decision PointsTemperature RangeAccuracyCost

LM35CAZPrice: $5.60Range: -40 to 110degCTemp. Error: +/- .3degCSupply Voltage: 4V to 30V


Choice #1

497-1583-1-NDPrice: $1.30Range: -40 to 100degCTemp. Error: +/- 1degCSupply Voltage: 2.98V


Choice #2

LM35CHPrice: $11.35Range: -40 to 110degCTemp. Error: +/- .5degCSupply Voltage: 4V to 30V


Choice #3

Final Selection: LM35CAZ Temperature Sensor

Internal Temp. Sensor

Function Units Temp. Range Accuracy Cost Total

Importance 5 5 4

LM35CAZ Rating 9 9 7 25Factor 45 45 28 118

497-1583-1-ND Rating 9 5 9 23Factor 45 25 36 98

LM35CH Rating 9 7 6 22Factor 45 35 24 104

Internal Temperature Sensor Decision Matrix

Gyroscope

SpecificationsMust measure in a 3-D coordinate system

Decision PointsInterfacingSensitivityMeasurement RangeTemperature RangeCost

Gyroscope

Choice #1

551-1080-1-NDPrice: $9.38Range: +/- 2000deg/secSensitivity: 1.33deg/secOperating Temp: -40 to 85degCVoltage Supply: 2.5V to 3.0VSize: 3.1x4.1x.83 mm^3

Gyroscope

Choice #2

L3G4200DPrice: $29.95Range: +/- 2000deg/secSensitivity: 70mdpsOperating Temp: -40 to 85degCVoltage Supply: 2.4V to 5.5VSize: .5x.9in

L3GD20Price: $8.48Range: +/- 2000deg/secSensitivity: 70mdpsOperating Temp: -40 to 85degCVoltage Supply: 2.4V to 3.6VSize: 4x4x1 mm

Gyroscope

Choice #3

Gyroscope Function Units

Interfacing Temp. Range

Sensitivity

Measurement Range

Cost Total

Importance 5 5 4 5 4

551-1080-1-ND Rating 6 9 5 9 7 36Factor 30 45 20 45 28 168

L3G4200D Rating 9 9 7 9 5 39Factor 45 45 28 45 20 183

L3GD20 Rating 5 9 7 9 8 38Factor 25 45 28 45 32 175

Gyroscope Decision Matrix

Final Selection: L34200D Gyroscope

Sensor’s DC/DC converter

SpecificationsOutput Voltage: 3.3V

Decision PointsInterfacing Power RatingOutput CurrentCost

IK1203SAPrice: $5.00Output Voltage: 3.3VOutput Current: 75.7 mAInput Voltage: 10.8V to 13.2VPower Rating: 250mWSize: .24x.46 in

Sensor’s DC/DC Converter

Choice #1

OKI-78SR-3.3/1.5-W36-CPrice: $4.39Output Voltage: 3.3VOutput Current: 1.5A Input Voltage: 7V to 36VPower Rating: 4.95WSize: .41x.65in


Choice #2

PT5103NPrice: $12.21Output Voltage: 3.3VOutput Current: 1AInput Voltage: 9V to 26VSize: 1x1.02in


Choice #3

Voltage Regulators Function Units

Power Rating

Interfacing Output Current

Cost Total

Importance 4 4 3 3IK1203SA Rating 9 8 7 9 33

Factor 36 32 21 27 116 OKI-78SR-3.3/1.5-W36-C

Rating 5 9 8 9 31Factor 20 36 24 27 107

PT5103N Rating 7 8 8 7 30Factor 28 32 24 21 105

Final Selection: IK1203SA DC/DC Converter

Sensor’s DC/DC Converter Decision Matrix

Computer’s DC/DC Converter

SpecificationsMust give a steady output voltage between

7V and 12VWant a Switcher

Decision PointsInterfacing Power RatingOutput Current Cost


Choice #1

JCA0212D02 Price: $18.20 Operating Range: -40 to

60degC Input Range: 9V to 18V Power: 2W Output Voltage: 12V


Choice #2

ISP1212A Price: $18.00 Operating Range: -40 to



Choice #3

NTFS1212MC Price: $12.11 Operating Range: -40 to


DC/DC Converters Function Units

Interfacing Power Rating

Output Current

Cost Total

Importance 4 5 3 3

JCA0212D02 Rating 8 6 8 7 31Factor 32 30 24 21 107

ISP1212A Rating 8 6 9 7 30Factor 32 30 27 21 110

NTFS1212MC Rating 9 9 8 9 35Factor 36 45 24 27 132

Computer’s DC/DC Converter Decision Matrix

Final Selection: NTFS1212MC

Accelerometer

SpecificationsMeasure in a 3D coordinate planeNeed to measure up to 8 G’s

Decision PointsInterfacing Sensitivity Number of AxesCost

ADXL312Price: $11.16Number of Axes: 3Range: ±12gSensitivity: 39 LSB/gBandwidth: up to 3.2kHz

Accelerometer

Choice #1

Accelerometer

Choice #2

BMA180Price: $29.95Number of Axes: 3Range: ±8gSensitivity: 1024 LSB/gBandwidth: up to 1.2kHz

Accelerometer

Choice #3

ADXL345Price: $7.75Number of Axes: 3Range: ±8g

Sensitivity: 57 LSB/gBandwidth: up to 3.2kHz

Accelerometer Function Units

Interfacing Sensitivity Number of Axes

Cost Total

Importance 3 5 5 4

ADXL312 Rating 7 4 9 7 27Factor 21 20 45 28 114

BMA180 Rating 9 9 9 6 33Factor 27 45 45 24 141

ADXL345 Rating 7 4 9 9 29Factor 21 20 45 36 122

Final Selection: BMA180 Accelerometer

Accelerometer Decision Matrix

Pressure Sensor

SpecificationsThe pressure sensor must be able to measure the

pressure at 30,480m or 100,000ft above sea level

Decision Points Interfacing Range Sensitivity Cost

Pressure Sensor

Choice #1

SSCSANN005PG3A3Price: $30.05Operating Range: -20 to

60degCInput Voltage: 3.3VAccuracy: 2%Measurement Range: 0psi

to 15psi

Pressure Sensor

Choice #2

MPX5100Price: $9.27Operating Range: -40 to

125degCInput Voltage: 5VAccuracy: 2.5%Measurement Range: 0 to

100kPa

Pressure Sensor

Choice #3

HSCDANN030PGAA5Price: $35.45Operating Range: -20 to

85degCInput Voltage: 5VAccuracy: 1%Measurement Range: 0psi

to 30psi

Pressure Sensor Decision Matrix

DC/DC Converters Function Units

Interfacing Range Accuracy Cost Total

Importance 4 5 3 3

SSCSANN005PG3A3 Rating 8 9 9 3 29Factor 32 45 27 9 113

MPX5100 Rating 6 8 5 8 27Factor 24 40 15 24 103

HSCDANN030PGAA5 Rating 6 9 7 3 25Factor 24 45 21 9 107

Final Selection: SSCSANN005PG3A3

Batteries

SpecificationsMust supply up to 4hrs of powerMust supply between 9V and 18V

Decision PointsWeightInterfacingTemperature RangeCost

Energizer Advanced LithiumPrice: $1.69/batteryRange: -40 to 60degCweight: 14.5gOutput Voltage: 1.5V

Batteries

Choice #1

Energizer Ultimate LithiumPrice: $2.27/batteryRange: -40 to 60degCweight: 14.5gOutput Voltage: 1.5V

Batteries

Choice #2

Kodak Max LithiumPrice: $1.97 /batteryRange: -40 to 60degCweight: 12gOutput Voltage: 3V

Batteries

Choice #3

Battery Names Function Units

Weight Temp. Range

Interfacing Cost Total

Importance 4 5 3 4

Energizer Advanced Lithium

Rating 8 9 9 9 35Factor 32 45 27 36 140

Energizer Ultimate Lithium

Rating 8 9 9 7 33Factor 32 45 27 28 132

Kodak Lithium Rating 9 9 6 8 32Factor 36 45 18 32 131

Final Selection: Energizer Advanced Lithium Batteries

Battery Decision Matrix

Testing

Burn In Test Breadboard the design and power the circuit

and see how long the batteries will last.

DC/DC converter test Test to make sure the DC converters are

outputting the right values.

Cold test Put the fully manufactured circuit inside the enclosure and

place the enclosure inside the cold lab.

Budget

Sensors(+shipping): $152.85Batteries: $80.00Battery Boxes: $6.00PC Board: $12.00Wires: $7.00

Total: $257.85

Mechanical System

Structural System

Thermal

StructureTemperature

MaterialVibrationsEnclosure

Attachment Impact

Mechanical System2012

Payload

Computer System

Electrical System

Mechanical System

Thermali. Must be similar to the MSU HASP Research Team structure materials

1. Polystyrene must be used for the insulation (approx. 1 cm thickness)

2. A shiny reflective aluminum coating should be applied

3. Additional material or support structures will be needed to make the structure strong

ii. The internal temperature of the payload must be kept between -40 C and 60 C

Structural Systemi. Enclosure

1. The external volume may not exceed 5.875 in x 5.875 in x 11.8 in (15 cm x 15 cm x 30 cm)

2. The internal volume must be at least 131.6 in3 : 4.5 in x 4.5 in x 6.5 in

ii. Vibrations1. Must be able to withstand frequencies of 20-2000 Hz

iii. Attach Enclosure Structure1. HASP

1. Enclosure must securely attach to HASP Plate and not be disconnected for the duration of the flight

2. Must be easily attached and unattached from the ASP plate for ease of assembly and disassembly

2. BOREALIS1. Must attach to the BOREALIS rope connection

systemiv. Impact Forces

1. Must withstand a vertical impulse force of 10 G’s2. Must withstand a horizontal impulse force of 5 G’s3. Must withstand a force of 7.25 G’s due to cross winds

at 100 Mph

Mechanical Systems Requirements

Temperature profile Estimated outside

Temperature of the Box

Radiation Energy from Space&

Radiation Energy from Earth(from ambient Temperatures of

the Earth and Sun)

Tearth = 293 KTspace = 2 K

Q As Tbox4 Tspace.earth

4

Thermal Considerations

Energy Balance

Qcond1 3 G Ab Qpower 2 Qspace Qearth

6Qcond2

G Ab Qpower 4 Qspace Qearth 6

Average theoretical Temperature inside the box with Rvalue = 3 m^2*K/W

TinQcond Rtotal

AtotalTbox

Trange2 = ( 33, -32 ) °CTrange1 = ( 40, -10 ) °C

(Sun hitting 3 sides) (Sun hitting 1 side)

Thermal Considerations

Reflective Material Emissivity (ε) Absorptivity (α) α/ε

Aluminum Foil 0.05 0.15 3

Reflective Aluminum Foil tape 0.05 0.15 3

Silver Reflective Tape 0.02 0.0044 0.22

Surface Properties

Decision Matrix: Reflective Material

Weight Factor Aluminum Foil Enerflex Reflective Foil

TapeSilver Reflective

Tape

Number Total Number Total Number Total Number Total

Cost 4 5 20 2 8 4 16 4 16

Ease Manufacturability 4 3 12 3 12 4 16 4 16Compliance w/ Research

Team 5 5 25 3 15 4.5 22.5 4 20Emissivity (lower =

better) 5 4 20 3.5 17.5 4 20 5 25

Availability 5 5 25 3 15 5 25 3 15

Reliability 4 3 12 3 12 4.5 18 4.5 18

Compatible with electronics 4 5 20 2 8 5 20 5 20

Totals 134 87.5 137.5 130

Decision Matrix – Reflective Material

Decision Matrix: Insulation

Weight Factor Polystyrene -

Extruded Polystrene - Expanded Polyisocyanurate

Number Total Number Total Number Total

Cost 4 3 12 4 16 3 12

Ease Manufacturability 4 4 16 4 16 4 16

Compliance w/ Research Team 5 5 25 5 25 4 20

Weight 3 3 9 3 9 3 9

Reliability 4 4 16 4 16 4 16

Surface tape can stick to 4 3 12 3 12 3 12

Compatible with electronics 4 5 20 5 20 5 20

Totals 110 114 105

Decision Matrix - Insulation

Insulator Material

Reflective Material

A.)

Insulator Material

Reflective Material

Fiber Glass Cloth

Insulator Material

Reflective Material

Plaskolite

B.) Fiber Glass Cloth

D.)

Insulator Material

Reflective Material

Plaskolite

C.)

Material Configuration

Decision Matrix: Structural Support - any number of these can be combined

Weight Factor Rebar (3/8) Rebar Wire Plaskolite Fiber glass cloth • L Bracket

Number Total Number Total Number Total Number Total •Number • Total

Cost 4 4 16 4.5 18 4 16 2 8 • 4 • 16

Ease Manufacturability 4 3 12 4 16 3 12 3 12 • 3 • 12

Added Strength 4 4 16 3.5 14 4 16 4.5 18 • 4 • 16

Interference with thermal properties of

insulation (lots of interference = bad)

4 1 4 5 20 5 20 4 16 • 4 • 16

Ease of integrating with other materials 3 3.5 10.5 4 12 4 12 4 12 • 4 • 12

Weight (low = better) 4 2 8 4 16 4 16 4 16 • 3.5 • 14

Availability 5 5 25 5 25 5 25 4 20 • 5 • 25

Reliability 4 5 20 4 16 3.5 14 5 20 • 4.5 • 18

Totals 111.5 137 131 122 • • 129

Decision Matrix – Structural Support

L Brackets for stability and form Rebar wire for stability and form

Structure Configurations

Reflective MaterialPlaskolite

Shell

Polystyrene - Extruded

Preferred Configuration – Material Placement

Preferred Configuration – Structural Support

Type of Test

*Drop Test

*Vibrametor Test

*Long Term Thermal Test

*Emittance Test

*Surface Thermal Test

What will be Tested

- Accelerometers- Structure components

-Structure components

-Insulation

-Reflective coating’s surface properties

-Heat transfer and absorptivity of insulation and reflective coating

Mechanical System - Testing

Mechanical Systems Mass Budget

Mechanical Systems Mass Budget Quantity Weight/Piece (g) Total Weight

Extruded Polystyrene 1 150 150

Plaskolite Polystyrene Light Panel 1 73 73

16.5 gauge Rebar Tie Wire 8 0.9925 7.94

Brackets 4 22.68 90.72

Bracket Mounting Hardware 8 26.84 214.72

HASP Mounting Material 1 232 232

CCA Stack Mounting Standoff 16 5.9 94.4

Total Mass 862.78

Material CostExtruded Polystyrene $12.25Plaskolite Polystyrene

Light Panel $6.4716.5 gauge Rebar Tie

Wire $4.25Reflective Aluminum Foil

tape $12.99Assembly Materials $38.40

Emergency Funds $30.64Total $105.00

Mechanical System Budget

Over-all Preliminary PreferredConfiguration

Project Mass Budget

PROJECT MASS BUDGETMay Not Exceed 1620 g

System Mass (g)

Mechanical Systems 862.78

Computer Systems 90.72

Electrical Systems 400

Systems Total 1353.5

Mass to be Added 266.5

PROJECT BUDGETNot to exceed $500

System Cost ($)Mechanical 105.00

Computer Science 62.70

Electrical 257.85

Total 425.55

Additional Funds Available 74.45

PROJECT BUDGET

Project Schedule

Documents

High Altitude Balloon Payload Design Project Summer 2012