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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 [email protected] 704-657-3866
Brad Hager [email protected] 704-500-9508
Michael Brown [email protected] 704-497-4225
John Benfield [email protected] 704-775-5530
Beau Brinkley [email protected] 704-902-0627
Nathan Keller [email protected] 704-872-2323
Samuel Fox [email protected] 704-928-5172
Derek Spencer [email protected] 704-883-4731
Dylan Stobbe [email protected] 828-278-9466
Ryan Howard [email protected] 704-663-2299
Joseph Edwards [email protected] 704-500-4003
Gary Staggers [email protected] 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