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Drexel RockSAT Preliminary Design Review Kelly Collett • Christopher Elko • Danielle Jacobson October 26, 2011

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Drexel RockSAT. Preliminary Design Review. Kelly Collett • Christopher Elko • Danielle Jacobson October 26, 2011. PDR Presentation Contents. Section 1: Mission Overview Mission Statement Mission Requirements Mission Overview Theory and Concepts Literature Review Concept of Operations - PowerPoint PPT Presentation

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Page 1: Drexel  RockSAT

Drexel RockSAT Preliminary Design Review

Kelly Collett • Christopher Elko • Danielle JacobsonOctober 26, 2011

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PDR Presentation Contents• Section 1: Mission Overview

• Mission Statement• Mission Requirements• Mission Overview• Theory and Concepts• Literature Review• Concept of Operations• Expected Results

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PDR Presentation Contents• Section 2: System Overview

• Physical Model• Critical Interfaces• Requirement Verification• User Guide Compliance

• Section 3: Subsystem Design• Energy Harvesting Subsystem• Structural Subsystem• Electrical Subsystem• Visual Verification Subsystem

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PDR Presentation Contents• Section 4: Prototyping Plan

• Projected Prototyping Process• Prototype Risk Assessment

• Section 5: Project Management Plan• Organizational Chart• Schedule• Budget• Work Breakdown Schedule• Sharing Logistics

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Mission OverviewDrexel RockSat Team 2011-2012

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Mission Statement

Develop and test a system that will use piezoelectric materials to convert

mechanical vibrational energy into electrical energy to trickle charge on-board power

systems.

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Mission RequirementsNumber Requirement

MIS-REQ-1000 Must be able to convert vibrational energy to electrical energy

MIS-REQ-2000 Must be able to withstand launch environments

MIS-REQ-3000 Final design must meet RockSAT specifications

MIS-REQ-4000 Must be functional during flight

MIS-REQ-5000 Must not interfere with canister partner’s design

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Mission Overview• Demonstrate feasibility of power generation

via piezoelectric effect under Terrier-Orion flight conditions

• Determine optimal piezoelectric material for energy conversion in this application

• Classify relationships between orientation of piezoelectric actuators and output voltage

• Data will benefit future RockSAT and CubeSAT missions as a potential source of power

• Data will be used for feasibility study

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Theory and Concepts• Piezoelectric Material

substance with linear electromechanical interaction between mechanical and electrical states in crystalline materials

• Piezoelectric Effectelectrical potential (voltage) developed within a piezoelectric material in response to an applied pressure or stress.

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Theory and Concepts continued

Where D is electric displacement, ε is permittivity,and E is electric field strength

Where S is mechanical strain, s is compliance,and T is mechanical stress

Superscript e denotes a zero/constant electric field;Superscript t denotes a zero/constant stress field;

d indicates piezoelectric constants

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Theory and Concepts continued

• Bonded to cantilevered aluminum strips with mass attached to free end

• Dynamic deflection under vibration andg-loading will create voltage potential

• Array of piezoelectric actuators

• Various orientations will account for vibrations in multiple directions http://en.wikipedia.org/wiki/Euler-

Bernoulli_beam_equation

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Theory and Concepts continued

• Place mass at end of beam to achieve maximum deflection under vibration

• Model with point load

Top: Bending Moment, M(x)Middle: Shear Force, Q(x)Bottom: Deflection, δ(x)

http://en.wikipedia.org/wiki/Euler-Bernoulli_beam_equation

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Theory and Concepts continued

• Uniform, distributed load when subjected to g-forces during launch

• Model with load acting along length of beam

Top: Bending Moment, M(x)Middle: Shear Force, Q(x)Bottom: Deflection, δ(x)

http://en.wikipedia.org/wiki/Euler-Bernoulli_beam_equation

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Theory and Concepts continued

• Electric potential (voltage) developed throughout piezoelectric actuators in AC form• AC voltage conditioned

using a full-bridge rectifier• Accumulated in a

capacitor• Monitored using a

voltmeter• Recorded using data

acquisition system (DAQ)http://en.wikipedia.org/wiki/Diode_bridge

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Literature ReviewPiezoelectric Generator Harvesting Bike

Vibrations Energy to Supply Portable Devices

E. Minazara, D. Vasic, and F. Costa• Piezoelectric generator that

harvests mechanical vibration energy and produces electricity

• Determined optimal band to harvest energy 12.5Hz• Modeled piezoelectric beam as spring mass damper

system• Produced ~3.5mW electricity

capable of powering LED

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Literature Review continued

Recent Progress in Piezoelectric Conversion and Energy Harvesting Using Nonlinear Electronic Interfaces and Issues in Small Scale Implementation

D. Guyomar and M. Lallart• Design of an efficient microgenerator must consider:

• Maximization of input energy• Maximization of electromechanical energy• Optimization of energy transfer

• Increase conversion abilities by:• Increase voltage• Reduce time shift between speed and voltage• Increase coupling term

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Literature Review continued

A Review of Power Harvesting Using Piezoelectric Materials

S. R. Anton and H. A. Sodano• PZT widely used

• Extremely brittle• Piezoceramics prone to fatigue crack growth when

subjected to high-frequency cyclic loading• PVDF exhibits considerable flexibility

• Flexible materials more beneficial• Practical coupling modes

• -31: Force applied perpendicular to poling direction• -33: Force applied in same direction as poling

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Literature Review continued

A Review of Power Harvesting Using Piezoelectric Materials

S. R. Anton and H. A. Sodano• High power output situations

• Stack configurations most durable in high-force environments

• When driving frequency is at resonant frequency of the system

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Literature Review continued

Comparison of Piezoelectric Energy Harvesting Devices for Recharging Batteries

H. A. Sodano and D. J. Inman• Researchers tested energy-harvesting qualities of

three different piezoelectric materials• Lead-zirconate-titanate (PZT)• Quick Pack bimorph actuator material (QP)• Macro Fiber Composite (MFC)

• Measured vibration of compressor, using piezo samples as accelerometers – output in volts• Full-bridge rectifiers used to condition signal from

oscillating AC into DC to charge batteries

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Literature Review continued

Comparison of Piezoelectric Energy Harvesting Devices for Recharging Batteries

H. A. Sodano and D. J. Inman• Efficiencies varied by material

• QP most effective for resonant frequencies (~8 to 9%)• PZT most effective for random vibrations (~4 to 4.5%)• MFC significantly less effective than PZT and QP

• Low-current, high-voltage output lacks the strength to charge batteries and is easily dissipated by diodes in circuit

• QP charged batteries fastest under resonant frequencies; PZT charged the best with random vibration.

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Literature Review continued

Piezoelectric Sea Power GeneratorR. M. Dickson• Operating principle

• Attempted to harness mechanical energy of waves as changes in pressure acting upon piezoelectric mats

• Minimally intrusive to ecosystem• Important implications for this project

• Studies show that static pressure alone does not induce a charge in piezoelectric materials

• Piezo arrays must be continuously deformed to create an electric potential that can be harvested

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Concept of Operations• G-switch will trip upon launch, activating all

onboard power systems• Batteries power Arduino microprocessor and data

storage unit• Data collection begins

• Vibration and g-loads on piezo arrays create electric potential registered on voltmeter• Current conditioned to DC through full-bridge

rectifier and run to voltmeter• Voltmeter output recorded to internal memory• Data gathered throughout duration of flight

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Concept of Operations• Data acquisition and storage will enable

researchers to monitor input from multiple sources• XY-plane vibrational energy• Z-axis vibrational energy

• Researchers will determine if amount of power generated is sufficient for the power demands of other satellites

• Include visual verification of functionality• Use energy from piezo arrays to power small LED• Onboard digital camera will verify LED illumination

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Expected Results• Piezoelectric beam array will harness enough

vibrational energy to generate and store voltage sufficient to power satellite systems

• Success dependent on following factors:• Permittivity of piezoelectric material• Mechanical stress, which is related to the

amplitude of vibrations• Frequency of vibrations

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System OverviewChristopher Elko

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Physical ModelMicrocontroller

Power Supply

Accelerometers

Piezo Arrays

Camera

Verification LED

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Subsystem IdentificationEPS – Electrical Power Subsystem

• Includes Arduino microprocessor, g-switch, accelerometers, voltmeter, battery power supply, and all related wiring

STR – Structural Subsystem• Includes Rocksat-C decks and support columns

PEA – Piezoelectric Array Subsystem• Includes piezoelectric bimorph actuators, cantilever

strips, mounting system, rectifier, and related wiring

VVS – Visual Verification Subsystem• Includes digital camera, LED, and all related wiring

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Critical InterfacesInterface Name Brief Description Potential Solution

EPS-STRThe electrical power system boards will need to mount to the RockSat-C deck to fix them rigidly to the launch vehicle. The connection should be sufficient to survive 20Gs in the thrust axis and 10 Gs in the lateral axes. Buckling is a key failure mode.

Past experiences show that stainless steel or aluminum stand-offs work well. Sizes and numbers required will be determined by CDR.

STR-PEAThe piezoelectric bimorph actuators must integrate into the structure without introducing a hazard to the operations of other satellite operation. The structure must also be designed such that the oscillatory motions of the piezo array cantilevers will not be impeded. Fracture is a key failure mode.

Testing will verify mounting methods and loading limitations of piezo actuators. Testing will also determine ideal range of deformation for maximum power generation.

PEA-EPSThe piezoelectric actuators must be wired correctly to ensure a voltage signal reaches the voltmeter and is registered by the DAQ.

AC signal may need to be conditioned to DC with a rectifier and amassed using an inline capacitor. Testing will verify whether parallel or series wiring should be used.

VVS-STRThe components (camera, LED) of the visual verification system must be mounted to the RockSat-C deck to fix them rigidly to the launch vehicle. The connection should be sufficient to survive 20Gs in the thrust axis and 10 Gs in the lateral axes.

Utilize stainless steel or aluminum standoffs, as in EPS-STR interface above.

VVS-PEA The LED component of the visual verification system must illuminate when a voltage is generated by the piezo arrays.

Wire LED in series with PEA to ensure proper illumination.

EPS-VVSThe camera component of the visual verification system must be powered from a steady, reliable source. Camera data must also be stored for playback after the flight.

Power camera from same battery source as microprocessor.

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Requirement VerificationRequirement Description Verification Method

The full system shall fit in the allotted space within the canister. Visual inspection will verify this requirement. Inspection

The system shall survive the vibration characteristics prescribed by the RockSAT-C program.

The system will be subjected to these vibration loads during preliminary testing on an associated institution’s vibration table, as well as in June during testing week.

Test

The power supply shall be engaged via the g-switch and all electronic systems powered on upon launch.

The minimum load needed to activate the g-switch and engage electronic systems will be calculated to ensure proper functionality under launch conditions.

Analysis

The piezoelectric actuators shall develop a recordable level of electric potential.

Preliminary testing will ensure a potential is developed when bimorph piezoelectric actuators are deformed.

Test

The microprocessor shall record and store all voltage, current, and visual data for duration of flight.

Arduino microprocessor will be programmed and checked to ensure proper collection of flight data prior to testing.

Demonstration

The camera shall record all activity the LED experiences.

The camera will be checked for functionality and successful integration into electrical system prior to testing.

Demonstration

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User’s Guide Compliance• Magnitude of mass to be determined by CDR• CG – to be determined based on design,

dictated by pre-CDR testing and validation• Low voltage electrical components used• No ports required

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Subsystem DesignStructural Subsystem

Christopher Elko

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Structural ComponentsRigid Mounting Deck Support Column

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Subsystem DesignEnergy Harvesting Subsystem

Christopher Elko

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Piezoelectric Actuators

Aluminum Cantilever

Mass

FastenerPiezoelectric Strip

Support Block

Redundant Assembly for Multi-plane Vibration

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Piezoelectric ActuatorsMounted to Lower Deck Attached with Fastener

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Subsystem DesignElectrical Power Subsystem

Danielle Jacobson

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Block DiagramPiezoelectric

Power OutputLED

Arduino Microcontroller

Camera

Power Supply

Rectifier

Piezoelectric Power Output LED

Rectifier

High-G Accelerometer

High-G Accelerometer

Low-G Accelerometer

Low-G Accelerometer

G-Switch

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Microcontroller• Arduino ATMEGA328 Microprocessor (Open

Source)• Record and store data on 2GB SD card

• Vibration data from accelerometers• Voltage output from piezoelectric materials

• Powered by four (4) AA replaceable batteriesOperating Voltage 5V

Input Voltage 6-20V

Digital I/O Pins 14 (6 can provide PWM output)

Analog Input Pins 6

DC Current per I/O Pin 40mA

DC Current for 3.3V Pin 50mA

Flash Memory 32KB 0.5KB used by boot loader

SRAM 2KB

EEPROM 1KB

Clock Speed 16MHz

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Accelerometers• Two (2) Low-G Accelerometers

• Analog Devices ADXL206 Dual-Axis• Two (2) High-G Accelerometers

• Analog Devices ADXL278 Dual-AxisLow-G Accelerometer High-G Accelerometer

Range +/- 5g +/- 35gSensitivity 312 mV/g 27mV/gOutput Type Analog Analog

Noise Density 110 µg/rtHz 180 µg/rtHzTemperature Range -40°C to 175°C -40°C to 105°CSize 13mm x 8mm x 2mm 5mm x 5mm x 2mm

Operating Voltage 4.25-5.25 V 4.25-5.25 V

Power 700 µV at VS=5V 2.2mA at Vs=5V

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Bridge Rectifier and G-Switch

• Bridge Rectifiers• Four (4) Diode Schottky 1A 20V MBS-1

• G-Switch• One (1) Omron Basic Roll Lever Switch SS-5GL2

Speed Recovery ≤ 500ns

Current 1 Amp

Voltage 20V Max at Peak Reverse

Temperature Range -55°C to 150°C

Operating Force 50 gf

Contact Rating 5A @ 125 VAC

Voltage 20V Max at Peak Reverse

Temperature Range -25°C to 85°C

Weight 1.6 g

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Subsystem DesignVisual Verification Subsystem

Kelly Collett

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Block Diagram

Piezoelectric Wire Output

LED

EPS Power Supply

Camera

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Camera Specifications• Runs on 12VDC, 100mA• Size: 0.98” sq. x 0.8”

IMAGING SPECIFICATIONSImager Manufacturer SonyLines 420Lux 0.0003

LENS SPECIFICATIONSMax FOV (degrees) 72Pinhole Yes

POWER REQUIREMENTSAmps DC (mA) 100Power Supply Included NoVolts DC Input 12

http://www.supercircuits.com/Security-Cameras/Micro-Video-Cameras/PC180XP2

Super B/W Microvideo Pinhole Camera

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LED Specifications• 5mm through-hole LED• 360-degree viewing angle• Low power consumption

http://www.superbrightleds.com/moreinfo/component-leds/5mm-white-led-360-degree-viewing-angle-4500-millilumens/341/1288

White 5mm LED

General Specifications

Lumen 4.5

Viewing Angle 360 deg

Wattage Consumption 0.064 W

Color Cool White

Color Temperature 7350 K

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Prototyping PlanChristopher Elko

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Prototyping Plan• STR

• Structural Subsystem will be designed and analyzed primarily using CAD and FEM techniques

• Prototype to be constructed and tested for fitment and mounting methods

• PEA• Piezoelectric actuators will be tested to determine

deformation limits and optimal deformation for energy harvesting

• Mounting/bonding methods to be explored upon construction of first prototypes

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Prototyping Plan continued

• EPS• Electronic interfaces will be table-tested with breadboard

and reconfigurable components• Testing will help to determine system capabilities

• VVS• Testing will help to determine system capabilities and

effects on other subsystems

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Prototype Risk Assessment

EPSFunctionality of

microcontroller must be verified by CDR

Prototype controller on bread board to verify

function

PEABond between PE

actuators and aluminum must not fail

Test various bonding materials and application

methods

STRConcerns exist about

clearance andcomponent mounting

Prototype all interfaces with STR to ensure

integrity

Risk/Concern ActionSubsystem

VVSLED must light, camera must not fail to record

actions of LED

Test LED with PEA toverify power draw;

test camera to ensure functionality

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Project Management PlanKelly Collett

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Organizational Chart

Danielle JacobsonElectrical Systems Lead

Machining

Christopher ElkoStructural Lead

CAD Designer

Kelly CollettVisual Verification Lead

Testing

Drexel SpaceSystems LabProject Support

Dr. Jin KangFaculty Advisor

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ScheduleNovember 201111/3

Order partsPiezo samples, electronics, structural materials

11/7PDR due

11/14Senior Design Written Proposal dueBegin Testing Samples (vibe, electronics)

11/17Senior Design Proposal Presentation

11/21Online Progress Report due

RockSat Deadlines • Drexel Deadlines

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Schedule continued

December 2011 – January 2012Continue testing and verification of all structures andparts for use in proposed assembly• Order additional parts as needed• Make necessary modifications12/8

CDR due1/9

Flights Awarded1/30

Online Progress Report due

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Schedule continued

FebruaryContinue testing and integration2/6 – Midterm Draft Report due2/13 – Subsystem Testing Reports due2/27 – Progress Presentation to Faculty Advisor

MarchContinue testing and integration3/12 – Online Progress Report due3/19 – Project Progress Report due

April3/9 – Senior Design Project Abstract due4/15 – Payload Canister ReceivedIntegration of components with canister

53

Estimated Spring Schedule

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Schedule continued

April, continuedFirst Full Mission Testing (vibration, etc.)4/23 – First Full Mission Simulation Test Report

Presentation dueMay

Continue Full Mission Testing and modificationsWeekly teleconferences5/14 – Final Senior Design Project Report due5/21 – Final Project Presentation5/28 – Launch Readiness Review (LRR) Presentation due5/30 – College of Engineering Project Competition

JuneWallops

Estimated Spring Schedule, continued

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Budget• Spending to date: $94.44• Estimated final total: $673.93

• Major Cost Contributors• Digital Camera - $109.99• Piezoelectric Components - $150

• Major Time Contributors• Piezoelectric Components – 7-10 days• Accelerometers – 7-10 days

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Budget continued

Item Subsystem Supplier Cost Lead Time

12"x12“Polycarbonate Sheet STR McMaster-Carr $7.23 1 day

+/- 35g Accelerometer EPS DigiKey $17.23 7-10 days

+/- 3g Accelerometer EPS DigiKey 7-10 days

G-Switch EPS DigiKey $2.15 7-10 days

Arduino ATmega 128 microprocessor EPS 7-10 days

Bridge rectifier EPS DigiKey 0.62 7-10 days

Piezo Electric Parallel Bimorph Actuator PEA Steminc $19.98/set of 2 7-10 days

Digital Camera VVS Super Circuits $109.99 3-5 days

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Budget continued

Item Subsystem Supplier Cost Lead Time

LED Lights VVS SuperbrightLEDs.com $1.59 3-5 days

TBD PIEZO MAT'L PEA – testing TBD $75 TBD

TBD PIEZO MAT'L PEA – testing TBD $75 TBD

TBD PIEZO MAT'L PEA – final installation TBD $150 TBD

TBD CIRCUITRY COMPONENTS EPS – testing TBD [DigiKey] $50 TBD

TBD CIRCUITRY COMPONENTS EPS – final installation TBD [DigiKey] $50 TBD

1/8" x 1" Rectangular Aluminum Stock STR McMaster-Carr $17.91 1 day

TBD STRUCTURAL MATERIALS STR TBD [McMaster] $50 TBD

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Sharing LogisticsTemple University• Plan for Collaboration

• Email, phone, campus visits• Full model designed in

SolidWorks for fit check• DropBox/Google Docs for

file sharing• Structural interface

• Consider clearance• Joining method

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ConclusionsWhat’s Next?

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Next Steps• Conduct functionality tests of

subsystems• PEA material strength testing• EPS functionality test

• Determine final materials to be used• Procure parts and begin assembly• Fabricate structures for assembly

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Thank you!Questions?