Preliminary Design Review Patrick Weber, Eric Robinson, Dorin Blodgett, Michael Stephens, Heather...

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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.


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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.


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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


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Concept of Operations


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


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


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Subsystem Overview


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System Level Block Diagram


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


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


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


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.


1711/1/2010

Subsystem Overview

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Subsystem A: Telescopic Boom

11/1/2010 Presenter: Patrick Weber

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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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o Telescopic Boom, Spring Loadedo Safe

o Inexpensive

o Reliable

o Strong


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


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Subsystem A: Water Shield

o Aluminumo Easily machined

o Inexpensive

o Reliable (no surprises)




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




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




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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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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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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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)




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.


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.



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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.



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


𝐼=∆ 𝑃=𝑚𝑣2−𝑚𝑣1𝐼=𝑚𝑣2

𝑣2 , 𝑦=−𝑔𝑡 , 𝑦=𝑦 𝑜−12𝑔𝑡


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Finite Element Analysis

o Simplified Governing Equations


(𝒌𝑘+𝒌𝑝+𝒌𝛼 )𝒅=𝒓𝑞+𝒓 𝛽

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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.


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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.


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.


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.


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Project Management Plan

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Organizational Chart


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


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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


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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)


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%)


Monetary Budget

Boom Water ShieldCamera Other SensorsModular Electrical System AerogelCorrecting Factor

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Work Breakdown Structure


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.


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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.


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