preliminary design review patrick weber, eric robinson, dorin blodgett, michael stephens, heather...
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1
Preliminary Design Review
Patrick Weber, Eric Robinson, Dorin Blodgett, Michael Stephens, Heather Choi, Kevin Brown, Ben Lampe
November 1, 2010
11/1/2010
211/1/2010
Mission Overview
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Scientific Mission Overview
o Primary: Collect space dust.o Provide a perspective of what is in our upper atmosphere.
o Secondary:o Capture optical images of the Earth.
o Measure thermal, seismic, and pressure effects throughout the duration of the launch.o Collect data for future projects.
11/1/2010 Presenter: Eric Robinson
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Engineering Mission Overview
o Engineer an extendable boom to mount a dust collector.
o Use aerogel tablet as dust collector.o Engineer a water shield to protect dust collector.
o Engineer modular electronic systems for:o Capturing and storing images from optical devices.
o Recording thermal, seismic, and pressure data in real time throughout launch using sensors and transferring recording data via provided NASA Wallops Telemetry.
11/1/2010 Presenter: Eric Robinson
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Theory and Concepts
o Underlying Science and Theoryo Attempt to capture space particles using telescoping boom and
aerogel.
o Quantification of varying flight parameters.
11/1/2010 Presenter: Eric Robinson
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Theory and Concepts
o Previous Experimentationo Previous flights have included multi-sensor packages.
o Temperature, Humidity, and Pressure Sensors
o Accelerometers / Seismic Sensors
o Magnetometers
o Data Storage (SD Cards)
o Results provided a basis for improvement on future data collection and retrieval.
o SD Cards impervious to low exposure to salt water
o Payload orientation
11/1/2010 Presenter: Eric Robinson
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Concept of Operations
11/1/2010 Presenter: Eric Robinson
t ≈ 0 minLaunch
t ≈ 0.7 minEnd of Orion Burn
t ≈ 1.7 minShedding of Skin
Boom Extendst ≈ 2.8 min
Apogee
t ≈ 4.0 minBoom Retracts
t ≈ 8.2 minChute Deploys t ≈ 15 min
Splash Down
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Expected Results
o Successfully collect space dusto Space Dust Composition (10-6)
o Exhausted Rocket Fuel
o Meteor / Metal Fragments
o Other Miscellaneous Gases
o Earth images
o Detailed data throughout flight duration
o Thermal Data
o Seismic/Vibration Data
o Atmospheric Pressure Data
11/1/2010 Presenter: Eric Robinson
911/1/2010
System Overview
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Subsystem Definitions
o TB: Telescopic Boom
o OC: Optical Camera
o IS: Integrated Sensors
o EPS: Electrical Power System
o STR: Structure
o MCU: Micro Controller Units
11/1/2010 Presenter: Eric Robinson
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Subsystem Overview
11/1/2010 Presenter: Eric Robinson
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System Level Block Diagram
11/1/2010 Presenter: Eric Robinson
Buck Converter
Boost Converter
Microcontroller
WFF Po
wer
Inte
rface
WFF Te
lem
.In
terfa
ce
Motor Controller
EPS
TB
OC
STR
Wallo
ps P
T
Interfaces
Low Voltage
High Voltage
Data/Control
Legend
ISCamera Pressure S.
Accelerometer
Thermal Sensor
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Critical Interfaces
11/1/2010 Presenter: Eric Robinson
Interface Name Brief Description Potential Solution
TB/STRTelescoping boom will have to be integrated rigidly to the RockSat-X deck and designed carefully to be shielded tight in order to preserve the dust collected throughout the duration of the flight.
The boom’s base is designed as part of the main structure, but must also be bolted to the top plate for extra support.
EPS/STRThe electrical system will need to be mounted to the RockSat-X deck rigidly to survive the thrust, vibrational, and impulse loading throughout the flight.
Using bolt fixtures, the circuit boards should be mounted to the structure.
IS/STRAll the sensors have to be integrated rigidly to the RockSat-X deck to withstand flight conditions.
The sensors should be mounted in the appropriate positions via epoxy or bolts.
OC/STRThe optical camera have to be mounted and shielded appropriately to survive throughout the flight.
The camera mount should have minimal deflection and vibrations will not affect the short exposure times. Therefore, a bolted mount should be sufficient.
TB/EPSThe telescoping boom is controlled by an electric motor. At motor stall, peak current is drawn, so overheating and overdrawing of current is the critical failure mode.
A standard cable should connect the motor controller to the EPS circuit board. All power connections will be fuse protected.
IS/EPSAll the data will be recorded and transmitted through provided telemetry. Telemetry failure is the critical failure mode.
IS electrical leads will interface with the EPS circuit board. All power connections will be fuse protected.
OC/EPSOptical camera will be controlled by electrical system. Short-circuiting and failure of the electrical communication is the critical failure mode.
Internal power lines will be securely mounted using epoxy. External lines will be designed by NASA. All power connections will be fuse protected.
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System/Project LevelRequirement Verification Plan
11/1/2010 Presenter: Eric Robinson
Requirement Verification Method
Description
The telescopic boom shall extend no more than 12” from the Payload’s outermost dimension and then seal itself shut upon retraction.
Demonstration Boom will extend to its full length and be retracted to verify all mechanical components function properly and gaskets effectively seal the interior from water.
The payload structure will survive 50G forces with minimal deflections during launch.
Analysis SolidWorks will be used to subject our payload structure to a 50G uniform acceleration to measure deflections.
The payload structure and gasket seals must survive the impact of splashdown completely intact and stay sealed during submersion.
Testing Payload structure with boom, motor, and locking mechanism will be impact tested and left submerged underwater to ensure structural soundness and gasket functionality.
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User Guide Compliance
11/1/2010 Presenter: Eric Robinson
Type Quantitative Constraint
Physical Envelope CylindricalDiameter: 12 inchesHeight: 6 inches
Weight 15 lbf ± 0.5 lbf
Center of Gravity (COG) ±0.5in from axial center of RockSat-X plate
Power and Telemetry 8x 0-5V 16-bit A/D Lines1x Asynchronous Line at 15.36 kBd (19.2 kBd nom.)One GSE Activation LineThree timer controlled power linesOne redundant timer controlled line
High Voltage No high voltage lines required.
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Sharing Logistics
o Who are we sharing with?o University of Northern Colorado
o Re-entry Experiment Sat: Recover a reusable deployable, attempt to dynamically control the descent of the payload, and gather data during the return trip.
o The possibility of a communication system between the AstroX payload and the UNC Re-entry Experiment Sat payload is being considered.
o Plan for collaboration?o Email, phone, road-trips to Greeley and Boulder
o Communication with Max Woods on a weekly basis.
o Grant UNC access to the AstroX private website.
11/1/2010 Presenter: Eric Robinson
1711/1/2010
Subsystem Overview
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Subsystem A: Telescopic Boom
11/1/2010 Presenter: Patrick Weber
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Subsystem A: Telescopic Boom
o Functional Block Diagram
11/1/2010 Presenter:
IRPD
Arduino Motor
Servo
Power FET
MotorPower Regulator
Opto Isolator
ArduinoPower Regulator
PWM
5v
PWM
ADC
28V 28V
5V
Shun
t Rel
ay
GPIO
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Subsystem A: Telescopic Boom
o Telescopic Boom, Spring Loadedo Safe
o Inexpensive
o Reliable
o Strong
11/1/2010 Presenter: Patrick Weber
Type Score Safety Cost Strength Reliability Weight Feasibility Complexity
Weighting Factor 3 8 9 9 8 9 8
Spring Loaded 399 8 8 7 8 5 8 8
Retractable Tray 329 10 5 7 6 5 6 6
Robotic Arm 247 8 3 6 5 5 4 3
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Subsystem A: Water Shield
11/1/2010 Presenter: Patrick Weber
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Subsystem A: Water Shield
o Aluminumo Easily machined
o Inexpensive
o Reliable (no surprises)
11/1/2010 Presenter: Patrick Weber
Type Score Safety Cost Strength Reliability Weight Feasibility Complexity
Weighting Factor 5 8 8 9 9 9 8
Aluminum 440 10 8 7 9 4 9 9
Composite 334 10 2 8 9 8 3 3
Plastic 394 10 5 4 7 9 8 7
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Subsystem B: Power System (EPS)
11/1/2010 Presenter: Michael Stephens
Wallops
ArduinoAutomation
MotorPower
ManagementMotor5-28V
Ratchet Servo5V5V
28V @ Launch
DL0
DL1
DL2
DL3
DL4
DL5
DL6
DL7
DL8
TI
T1
T2
T3
T4
5V
5V
5V
5V
5V
X/Y/Z Acc Board
5V
Pressure 5V
CameraCamera Power
Regulation3V28V @ Launch
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Subsystem B: Power System (EPS)
o NASA Powero Reliable
o Inexpensive
o No weight penalty
o Safe
11/1/2010 Presenter: Michael Stephens
Type Score Safety Cost Strength Reliability Weight Feasibility Complexity
Weighting Factor 5 6 7 9 7 9 9
NASA Power 520 10 10 10 10 10 10 10
Battery Packs 199 4 3 4 3 1 6 5
Solar Panels 247 10 1 2 8 6 2 5
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Subsystem C: Integrated Sensors
o Telemetryo Reliable
o Least Expensive
o No weight penalty
o Least Complex
o Cannot handle large data
11/1/2010 Presenter: Michael Stephens
Type Score Safety Cost Strength Reliability Weight Feasibility Complexity
Weighting Factor 3 4 7 9 5 9 8
SD Card 405 10 8 8 9 9 9 10
Telemetry 450 10 10 10 10 10 10 10
Eye-Fi 324 10 5 8 7 9 6 7
o SD Cardso Reliable / Redundant
o Solid State
o Impervious to salt water
o Lightweight
o Can handle large data
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Subsystem C: Integrated Sensors
11/1/2010 Presenter: Michael Stephens
TI Data logger A[0]
T1 Data logger A[1]
T2 Data logger A[2]
T3 Data logger A[3]
T4 Data logger A[4]
Pressure Data logger A[5]
X/Y Acc
Data loggerX A[6]
Data logger A[7]Y
Z Acc Data logger A[8]
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Subsystem C: Integrated Sensors
11/1/2010 Presenter: Michael Stephens
DL3
DL0
DL6
DL4
DL1
DL7
DL5
DL2
DL8
T1
T2
T3
T4
X/Y Z
Wallops Interface
Arduino Motor Controller
TI Pressure
IRPD
Bottom Top
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Subsystem C: Integrated Sensors
11/1/2010 Presenter: Michael Stephens
SD Card3.3 V Regulator
5V Regulator Atmega 324P5V
3.3 V
Scr
ew T
erm
inal
s
Vin
VIn
Vout
Sensor Board
28 V
Level Shifter
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Subsystem D: Optical Camera
o Optical Still Camerao Least Expensive (already own)
o Lightweight
o Least complex (circuits pre-engineered)
11/1/2010 Presenter: Michael Stephens
Type Score Safety Cost Strength Reliability Weight Feasibility Complexity
Weighting Factor 2 8 9 8 5 9 8
Infrared 355 10 2 7 6 8 8 8
Optical 371 10 10 7 6 8 8 8
Stereoscopic 301 10 1 7 8 4 6 7
3011/1/2010
Mathematical Models
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Telescopic Boom
o Launch/Reentryo Centrifugal Loading
o Static Tension
o Assumptionso The maximum centrifugal force will occur directly before Orion
burn out.
o Internal forces are equal to zero.
o Centrifugal masses are treated as point masses at their COG.
11/1/2010 Presenter: Patrick Weber
𝑮𝒐𝒗𝒆𝒓𝒏𝒊𝒏𝒈 𝑬𝒒𝒖𝒂𝒕𝒊𝒐𝒏𝒔 :
∑ 𝐹 h𝑙𝑎𝑢𝑛𝑐 /𝑟𝑒𝑒𝑛𝑡𝑟𝑦=𝐹𝑐𝑒𝑛𝑡𝑟𝑖𝑓𝑢𝑔𝑎𝑙+𝐹 𝑠𝑝𝑟𝑖𝑛𝑔
𝐹 𝑐𝑒𝑛𝑡𝑟𝑖𝑓𝑢𝑔𝑎𝑙=𝑚 (𝜔𝑟 )2
𝑟
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Telescopic Boom
o Apogeeo Spring Force
o Friction
o Dynamic Tension
o Assumptionso The maximum frictional force will occur between the base and
mid sections.
o Internal forces are zero.
o Gravity at apogee will be negligible, beam theory does not apply.
11/1/2010 Presenter: Patrick Weber
𝑮𝒐𝒗𝒆𝒓𝒏𝒊𝒏𝒈 𝑬𝒒𝒖𝒂𝒕𝒊𝒐𝒏𝒔 :
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Payload Structureo Launch
o Uniform Thrust Loading
o Vibrations
o Impulse
o Fatigue (~0.7 minutes)
o Pressure Vessel Effects (neg.)
o Assumptionso Loading can be applied as body forces.
o Payload internal supports are fixed connections.
o Payload has uniform material properties.
o Vibrations treated as static loads at peak amplitude.
11/1/2010 Presenter: Patrick Weber
𝑮𝒐𝒗𝒆𝒓𝒏𝒊𝒏𝒈 𝑬𝒒𝒖𝒂𝒕𝒊𝒐𝒏𝒔 :
𝛿=𝐹𝐿𝐴𝐸
𝜃=𝑇𝐿𝐽𝐺
𝑘=𝐹𝑥
=𝐺𝐽𝐿
𝐼=∫𝐹 𝑑𝑡 𝐹=𝑚𝑎
∑ �⃑�=0∑𝑀 𝑥 ,𝑦 , 𝑧=0
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Payload Structure
o Reentryo Impact
o Pressure Vessel
o Shear Loading (Plate Lip)
o Assumptionso Perfectly rigid and joints have no clearance
o Uniform material properties
o Gravity is constant
11/1/2010 Presenter: Patrick Weber
𝐼=∆ 𝑃=𝑚𝑣2−𝑚𝑣1𝐼=𝑚𝑣2
𝑣2 , 𝑦=−𝑔𝑡 , 𝑦=𝑦 𝑜−12𝑔𝑡
𝑮𝒐𝒗𝒆𝒓𝒏𝒊𝒏𝒈 𝑬𝒒𝒖𝒂𝒕𝒊𝒐𝒏𝒔 :
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Finite Element Analysis
o Simplified Governing Equations
11/1/2010 Presenter: Patrick Weber
(𝒌𝑘+𝒌𝑝+𝒌𝛼 )𝒅=𝒓𝑞+𝒓 𝛽
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Finite Element Analysis
o Launch Assumptionso Vibration loads will be treated as static loads at peak amplitude.
o Base of each longeron is fixed and immovable.
o No surface forces are present other than contact forces.
o Vibration and thrust loads are applied as body forces.
o Loading conditions are continuous over each part.
o All materials are linear isotropic.
11/1/2010 Presenter: Patrick Weber
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Finite Element Analysis
o Reentry Assumptionso Payload falls directly onto surface.
o Surface is perfectly rigid.
o Payload can deform.
o No surfaces forces are present other than part contact forces and surface/payload contact force at impacting location.
o Drag and impact loads are applied as body forces.
o All materials are linear isotropic.
11/1/2010 Presenter: Patrick Weber
3811/1/2010
Prototyping Design
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Subsystem: Risk Matrix/Mitigation
o Risk Matrix / Mitigationo STR/TB.RSK.1: Canister seals fail
at splashdown and aerogel issaturated with water.
o TB.RSK.2: Boom jams when skinsare shed. Boom fails to open andmission objectives are not met.
o IS.RSK.1: Telemetry or SD cards fail and data to be collected for next year’s team is lost. Secondary mission objectives are not met.
o EPS.RSK.1: Should the NASA telemetry or Timed Event circuits fail, the boom may prematurely extend causing failure of the UW payload as well as possible damage to the rocket.
11/1/2010 Presenter: Patrick Weber
Consequence
EPS.RSK.1 STR/TB.RSK.1TB.RSK.2
IS.RSK.1
OC.RSK.1
Possibility
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Prototyping Plan
o Most mechanical prototyping will be done and tested using Finite Element Analysis. o Drop tests
o Launch simulations
o Once the payload is manufactured, extensive testing will be performed on the payload as it is assembled.o Circuits tests
o Pool submersion tests on the canister as well as drop deflection tests on the sealing around the boom.
11/1/2010 Presenter: Patrick Weber
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Project Management Plan
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Organizational Chart
11/1/2010 Presenter: Patrick Weber
Project ManagerShawn Carroll
Team LeaderPatrick Weber
Physics Faculty AdvisorDr. Paul Johnson
Engineering Faculty AdvisorDr. Carl Frick
Integrated Sensors (IS)Michael Stephens
Heather Choi
Electrical Power System (EPS)Michael Stephens
Ben Lampe
Telescopic Boom (TB)Patrick WeberEric RobinsonDorin Blodgett
Optical Camera (OC)Kevin BrownNick Roder
Charles Galey
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Mechanical Schedule
o Major Mechanical Milestones:o Design Freeze at CDR (Friday, November 19, 2010)
o Blueprints submitted for manufacturing by CDR
o Mechanical prototype constructed mid-January, 2011
o Mechanical prototype fully tested by end of January, 2011
o Impact and submersion testing
o Aerogel testing
11/1/2010 Presenter: Patrick Weber
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Electrical Schedule
o Major Electrical Milestones:o Electrical Schematics completed by CDR
o Components ordered by end of Fall Semester (December, 2010)
o Electrical assembly and testing done by Mid February
o Control function test
o Telemetry and SD card output test
o Fully functioning payload by end of February
11/1/2010 Presenter: Patrick Weber
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Budget
o Mass Budget (15±0.5 lbs)o Structure (9 lbs)
o Boom (2 lbs)
o Water Shield (4 lbs)
o NASA Structure (3 lbs)
o Camera (1 lb)
o Other Sensors (1 lb)
o Modular Electrical System (1 lb)
o Ballasting (~3 lbs)
11/1/2010 Presenter: Patrick Weber
Mass Budget
Boom Water ShieldNASA Structure CameraOther Sensors Modular Electrical SystemBallasting
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Budget
o Monetary Budget (~$1300)o Structure ($600)
o Boom ($200)
o Aerogel ($300)
o Water Shield ($100)
o Camera ($100)
o Other Sensors ($110)
o Modular Electrical System ($200)
o Correcting Factor (+$25%)
11/1/2010 Presenter: Patrick Weber
Monetary Budget
Boom Water ShieldCamera Other SensorsModular Electrical System AerogelCorrecting Factor
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Work Breakdown Structure
11/1/2010 Presenter: Patrick Weber
Integrated Sensors (IS)
Electrical Power System (EPS)Telescopic Boom (TB)
Optical Camera (OC)
• Finalize Design• Design Freeze at CDR• Submit Work Request• Manufacture Boom Parts• Assemble Boom and Structure
• Finalize Schematics• Design Freeze at CDR• Order Parts by End of Fall Semester• Build Circuits• Program Microcontrollers• Test Systems• Integrate with Boom
• Finalize Schematics• Design Freeze at CDR• Order Parts by End of Fall Semester• Build Circuits• Program Microcontrollers• Test Systems
• Recover previous year’s camera• Test functionality of camera• If functional:
• Integrate with Electrical Power System and Integrated Sensors
• If non-functional:• Assess alternatives and proceed in the
most appropriate path
4811/1/2010
Conclusions
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Scientific Mission Overview
o Primary: Collect space dust.o Provide a perspective of what is in our upper atmosphere.
o Engineer a water shield to protect dust collectors.
o Secondary:o Capture optical images of the Earth.
o Measure thermal, seismic, and pressure effects throughout the duration of the launch.o Collect data for future projects.
11/1/2010 Presenter: Patrick Weber
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Engineering Mission Overview
o Engineer an extendable boom to mount imaging equipment and dust collector.
o Use aerogel to collect space dust.
o Engineer modular electronic systems for:o Capturing and storing images from optical devices.
o Recording thermal, seismic, and pressure data in real time throughout launch using sensors and transferring recording data via provided NASA Wallops Telemetry.
11/1/2010 Presenter: Patrick Weber
Questions?