Detailed Design Review Team Members:Josh Benton Nathan Bialke Sean Bradburn Liana Garbowski Robert...

Detailed Design Detailed Design ReviewReview

Team Members:Team Members: Josh BentonJosh BentonNathan BialkeNathan BialkeSean BradburnSean BradburnLiana GarbowskiLiana GarbowskiRobert LaneRobert LaneGarrett ManfullGarrett Manfull

Presented To:Presented To: Marc MurbachMarc Murbach

March 1, 2007

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Project ValueProject Value

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SOAREXSOAREX

►Aligned with SOAREX goalsAligned with SOAREX goals

Sub-orbital atmospheric experimentationSub-orbital atmospheric experimentation

Innovative method of data gatheringInnovative method of data gathering

Improved understanding of atmospheric Improved understanding of atmospheric data collection without conventional data collection without conventional sensorssensors

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Future Use PotentialFuture Use Potential

► Atmospheric data collection – other Atmospheric data collection – other planetsplanets

SmallSmall Relatively inexpensiveRelatively inexpensive ExpendableExpendable

► Mars lander missionsMars lander missions Improved landing accuracy through real-Improved landing accuracy through real-

time atmospheric data collectiontime atmospheric data collection

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System OverviewSystem Overview

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System OverviewSystem Overview

►Atmospheric data collection deviceAtmospheric data collection device Activation: redundant mechanical Activation: redundant mechanical

switching upon ejectionswitching upon ejection Data transmission: radar transponder and Data transmission: radar transponder and

radar antenna; data tracked by ground radar antenna; data tracked by ground basebase

Thermal protection: spherical Teflon probe Thermal protection: spherical Teflon probe body enclosing all componentsbody enclosing all components

Data extraction: atmospheric properties Data extraction: atmospheric properties backed out through software math modelbacked out through software math model

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Mechanical ReviewMechanical Review

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Mechanical OverviewMechanical Overview

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Probe Body – Bottom ShellProbe Body – Bottom Shell

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► StrengthsStrengths

Concentration of mass ensures probe will fall in a Concentration of mass ensures probe will fall in a “bottom-first” orientation“bottom-first” orientation

Single-material constructionSingle-material construction► Solves coefficient of expansion problemsSolves coefficient of expansion problems► No delaminationNo delamination

Teflon advantagesTeflon advantages► Highly machinableHighly machinable► Favorable heating propertiesFavorable heating properties

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► Improvements neededImprovements needed

Mass reduction (bottom is ~8 lbs. by Mass reduction (bottom is ~8 lbs. by itself)itself)

Potential heat-related design revisionsPotential heat-related design revisions►Awaiting completion of heat modelingAwaiting completion of heat modeling

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►Potential failure modesPotential failure modes

Excess ablation rendering data useless or Excess ablation rendering data useless or complete meltdowncomplete meltdown

►Actions taken: analytical heat modeling, Actions taken: analytical heat modeling, possibly arc-jet testingpossibly arc-jet testing

Separation from upper shellSeparation from upper shell►Actions taken: Metal Key-sert threaded inserts Actions taken: Metal Key-sert threaded inserts

used to strengthen attachment pointsused to strengthen attachment points

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Probe Body – Top ShellProbe Body – Top Shell

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““Shelled out” design ensures mass will be Shelled out” design ensures mass will be significantly less than bottom half of spheresignificantly less than bottom half of sphere

Constructed from TeflonConstructed from Teflon► Same expansion coefficient as bottom shellSame expansion coefficient as bottom shell► Same favorable heating properties as bottom shellSame favorable heating properties as bottom shell

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Mass reduction (possibly change to a less-Mass reduction (possibly change to a less-dense material with a similar coefficient of dense material with a similar coefficient of expansion)expansion)

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Heat-related failure, allowing deformation Heat-related failure, allowing deformation or separation from bottom shellor separation from bottom shell

►Actions taken: “worst-case” heat modelingActions taken: “worst-case” heat modeling

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Switch AssemblySwitch Assembly

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Activation requires 2 of 3 switches to activateActivation requires 2 of 3 switches to activate► Protection from premature single-switch activationProtection from premature single-switch activation► Protection from single-switch failureProtection from single-switch failure

Switch operation not reliant on probe orientation Switch operation not reliant on probe orientation in foamin foam

Moving parts ejected from probe upon activationMoving parts ejected from probe upon activation

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► Improvements needed:Improvements needed:

(Possibly) longer activation plungers and (Possibly) longer activation plungers and springs to meet 2” extension-before-springs to meet 2” extension-before-activation criteriaactivation criteria

Possible relocation of activation points at Possible relocation of activation points at different locations on probe bodydifferent locations on probe body

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Switch AssemblySwitch Assembly►Potential failure modesPotential failure modes

Heat-related failure prior to activationHeat-related failure prior to activation►Actions taken: plunger holes slightly oversized for Actions taken: plunger holes slightly oversized for

thermal expansion/contractionthermal expansion/contraction

Early activationEarly activation►Actions taken: redundant switch setup, simple 1-Actions taken: redundant switch setup, simple 1-

moving-part design, switches locked in fully-moving-part design, switches locked in fully-depressed position before activation, backing depressed position before activation, backing plate to be placed in foam above switch area to plate to be placed in foam above switch area to prevent foam erosionprevent foam erosion

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Electrical ReviewElectrical Review

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Electrical OverviewElectrical Overview

►System schematicSystem schematic

Battery 1(4x Lithium Ion)

Battery 2(4x Lithium Ion)

RedundantBattery

Controller

SwitchingMechanism

(3x switches inmajority votingconfiguration)

VoltageRegulator

(14.4V to 28V)

RadarTransponder

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BatteriesBatteries

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BatteriesBatteries

►StrengthsStrengths

Two independent 14.4V lithium ion Two independent 14.4V lithium ion battery packs, each capable of powering battery packs, each capable of powering probeprobe

Battery controller isolates battery packsBattery controller isolates battery packs

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BatteriesBatteries


Potential mass reduction, if necessaryPotential mass reduction, if necessary Size reduction or arrangement Size reduction or arrangement

reconfigurationreconfiguration

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BatteriesBatteries


Battery failure, loss of voltageBattery failure, loss of voltage►Actions taken: Use of two redundant battery packs; Actions taken: Use of two redundant battery packs;

either one can completely power probeeither one can completely power probe Reversed battery polarityReversed battery polarity

►Actions taken: Battery controller will isolate Actions taken: Battery controller will isolate backwards battery from properly installed battery, backwards battery from properly installed battery, which will power probewhich will power probe

Failure of electrical connectionsFailure of electrical connections►Actions taken: : Connections made with terminal Actions taken: : Connections made with terminal

blocks using mechanical compression rather than blocks using mechanical compression rather than solder solder

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BatteriesBatteries

►Potential failure modes, continuedPotential failure modes, continued

Thermal-related failure resulting in Thermal-related failure resulting in explosion or fire from overcharge or over-explosion or fire from overcharge or over-dischargedischarge

►Actions taken: Battery controller prevents Actions taken: Battery controller prevents overvoltage, undervoltage, and completely overvoltage, undervoltage, and completely isolates two battery packsisolates two battery packs

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Radar Transponder/AntennaRadar Transponder/Antenna

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Radar Transponder/AntennaRadar Transponder/Antenna

► Supplied componentsSupplied components

Problem: The components are Problem: The components are notnot verifiable verifiable – UI doesn’t have any mechanisms for – UI doesn’t have any mechanisms for testing a radar transponder or antennatesting a radar transponder or antenna

Solution: Currently an open issue – will Solution: Currently an open issue – will require attention at NASA Ames for require attention at NASA Ames for verification verification

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ModelingModeling

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Heat ModelHeat Model

► Fay-Riddell:Fay-Riddell:

ρ, V from Robert’s trajectory modelρ, V from Robert’s trajectory model

► To find stagnation point temperature:To find stagnation point temperature:

Can then determine ablation – significant after ~400 Can then determine ablation – significant after ~400 degrees Cdegrees C

1.3** VRn

kqconv

tCVol

Ah

TT

TtT

p

S

initial **

*exp

)(

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Heat ModelHeat Model

► Linear Ablation:Linear Ablation:

S – linear ablationS – linear ablation ρρ∞∞ - free stream density - free stream density R – nose radiusR – nose radius VV∞∞ - free stream - free stream

velocityvelocity

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4.010*9.4

*10*28.1

V

VRS

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Trajectory ModelTrajectory Model

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AblationAblation

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System Functionality System Functionality StatusStatus

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Mechanical FunctionalityMechanical Functionality

►Probe body – bottom shellProbe body – bottom shell Integration with components functional; Integration with components functional;

awaiting heat modeling to verify designawaiting heat modeling to verify design

►Probe body – top shellProbe body – top shell Status same as bottom shellStatus same as bottom shell

►Switch assemblySwitch assembly Fully functional and undergoing failure Fully functional and undergoing failure

testingtesting

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Electrical FunctionalityElectrical Functionality

►BatteriesBatteries Functional and in our possessionFunctional and in our possession

►Radar TransponderRadar Transponder Awaiting deliveryAwaiting delivery

►Radar AntennaRadar Antenna Awaiting deliveryAwaiting delivery

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Open IssuesOpen Issues

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Open IssuesOpen Issues

► Weight – too great?Weight – too great? Increased ballistic coefficient; increased heatingIncreased ballistic coefficient; increased heating Do we need to change to a different material?Do we need to change to a different material?

► Modeling not yet completeModeling not yet complete

► Final design dependent on results of modelingFinal design dependent on results of modeling Must withstand heatingMust withstand heating Must be able to generate useful dataMust be able to generate useful data

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Budget ReportBudget Report

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BudgetBudget

Polymer Plastics $367.26Tenergy Corporation $200.22Tri-State $3.87Polymer Plastics $728.70MSC $337.76Battwery Space $30.47Spark Fun $14.58Mouser Electronics $42.57Furturtec $21.50ALCOBRA $35.14Mouser Electronics $41.10Fastenal $32.81Fastenal $76.21

ME $1,803.47EE $87.62Travel Set Aside $1,000.00

Total Expense $1,932.19Balance Left $4,423.81

Budget

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Battery Controller SchematicBattery Controller Schematic

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Voltage Regulation Voltage Regulation SchematicSchematic

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