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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.