RamRackPreliminary Design Review

Colorado State UniversityZach Glueckert

Christopher Reed

Timothy Schneider

Brendan Sheridan

Christina Watanuki

Advisor: Dr. Azer Yalin

November 14, 2008

RockSat 2008-2009

Objective: To develop a sounding rocket payload to act as a power bus, data logger, and mounting structure for future scientific payloads

Overview:•Power bus will be programmable to provide varying voltage supplies depending on need. •Data logger will provide a broad range of low level sensor communication and will contain several redundant systems. •Design will incorporate several permanent sensors that can be used to monitor conditions of this and future flights

Success Criteria: On this initial flight sensor data will provide data on conditions in the immediate region of the payload

Benefits: This information will be used to create constraints on future experimental payloads and help characterize the flight dynamics.

Overview

System Design

RamRack

Structure

PowerData Loging/Control

Sensors

ElectronicStructural

Connection Type

Subsystem - Structural

• Requirements– Must utilize the five 8-32 mounting holes available on the can– Highly adaptable mounting points for future payloads– Use as little space as possible while still providing adequate

mounting points for future payloads– Non-magnetic– Will not yield under a 40-g acceleration with a 10 pound load– Conform to RocketSat flight requirements– Weigh less than 1lb

• Design Drivers– Adaptability– Material Strength versus Weight– Size

Subsystem – Power Supply

• Requirements– Minimum supply voltage of 5V– Maximum supply voltage of 15V– Provide 15W for 1hr– Allow for brief but large current loads <5A– Redundant– Adjustable voltage output– Thermal monitoring with shutdown capabilities

• Design Drivers– Future payloads will have diverse power requirements

• Trying to allow for a broad range in order to be adaptable

– Weight– Size

Subsystem – Data Logger

• Requirements– Survive the physical characteristics of flight– Multiple ADC channels capable of 16 bit conversions– Multiple serial input channels– Easy data transfer– Redundancy in case of component failure– Sample Rates of 100Hz or better– Storage for all of the ADC channels at maximum sample rate for

one hour.

• Design Drivers– Maximize the amount of ADC Channels for future sensors– Ease of use – no special abilities required for future use– Cost

Subsystem – Sensors

• Requirements– Measure G-forces on three axis

• Fine measurement for low accelerations (+/-3g)• Gross measurements for large accelerations (+/-40g)

– Pressure (15-151 kPa)– Temperature of Operating Components– Vibration (10-300 Hz)

• Design Drivers– Test out our data logging system– Characterize Rocket Flight for future missions– Cost

Block Diagram - Power

Battery

Battery

Voltage Regulator

Voltage Regulator

Voltage Regulator

Voltage Regulator

Voltage Regulator

Voltage Regulator

G - Switch

G - Switch

Data Logger and Control Circuit Requirements

Sensor Package

Block Diagram – Data Logger

Power Sensor Package

Data Log One

Data Log Two

Temperature Sensor

Temperature Sensor

Block Diagram – Sensors

Power

z

y

x

Gross GSensor

Gross GSensor

Gross GSensor

Fine G Sensor

Pressure

Data Logger and Control Circuit Requirements

Vibration

Structural

• Structural– Al 6061 T6– Weight Estimate 6 oz– Integrates to holes

available in can– All components attach to

frame

• Electronic Enclosure• Battery Pack• In RockSat Can

Structural

Structural

Data Logger and Control

Data Logger and Control

Top Side Bottom Side

Data Logger and Control

Sensors

• Beginning work on mounting and sensor circuitry– Selected the sensors– Verified they will work with data logging unit

• Will be mounted on top of the RamRack– Can be placed in many different areas in order to make room for

other payloads

Command and Control

•In-House Software: Front-End

•Development planned in C++

•Data parser for .txt formatted file dump

•Generates time-stamps for each reading based on frequency settings and internal clock

•Splits data into separate graph-ready files for each input channel

•Interface for changing input/frequency settings

•Intuitive graphic user interface for ease of use by future groups

•Will take advantage of standard C++ GUI libraries (GTK+)

•Settings for each input channel saved in txt format and later piped to embedded systems

Command and Control

•In-House Software: Back-End

•Control unit programmed in a combination of tiny-BASIC and assembly

•Software for selecting and piping data from multiple input channels in real-time based on internal clock

•Must incorporate input and frequency settings from front-end software

•Must handle collisions appropriately

Command and Control

•Memory Budget•4 GB Micro SD Card

•Allows for sampling of 50kHz•Stores data from all 10 16 ADC Channels

Test Plan

• Subsystem Testing - Benchtop– Test each sensor individually– Integrate and make sure they are all recording data and working

• Calibration Testing– May have an opportunity to use the Air Force’s vibration facility– Drop Tests for G testing

• Practical Testing– Car Test

• Drive around with unit in vehicle and see if the data is reasonable• Allows for a time based test and requires the unit to be self-reliant

Parts List

part # # needed $ min Quant # to order

ATMEGA2561-16AU-ND 3 $15.91 1 3 47.73

ATMEGA8515-16AU-ND 4 $5.16 1 4 20.64

296-9225-5-ND 4 $0.72 1 4 2.88

296-9182-5-ND 2 $0.60 1 2 1.2

ADS7805U-ND 3 $31.07 1 3 93.21

576-1761-5-ND 16 $1.24 25 25 31

0

490-1631-1-ND 3 $0.22 10 10 2.2

399-1097-1-ND 15 $0.08 10 20 1.66

399-4788-1-ND 18 $1.04 10 20 20.8

493-2400-1-ND 6 $0.20 10 10 2

0

576KXBK-ND 3 $0.10 5 6 0.588

33.2KXBK-ND 3 $0.10 5 6 0.6

200XBK-ND 3 $0.10 5 6 0.6

P6.04KCCT-ND 16 $0.09 10 25 2.25

P1.5KDACT-ND 16 $0.20 10 25 5

RHM1.60KCCT-ND 30 $0.03 10 50 1.5

0

3361S-503GLFCT-ND 6 $1.02 1 6 6.12

CAT5113VI-10-T3CT-ND 18 $1.92 25 25 48

0

0

475-2506-1-ND 10 $0.13 1 10 1.33

475-1408-1-ND 10 $0.13 1 10 1.3

475-1196-1-ND 10 $0.13 1 10 1.3

0

A26508-40-ND 3 $2.32 1 3 6.96

929850E-01-36-ND 3 $3.31 1 3 9.93

A26532-40-ND 2 $4.22 1 2 8.44

929852E-01-36-ND 2 $6.33 1 2 12.66

0

HM152-ND 1 $10.94 1 1 10.94

0

http://www.saelig.com/ 0

uALFAT-TF 4 $35.95 1 4 143.8

Total 484.64

Part # # Needed Price Min Quant # Order Total PriceMMA2201D-ND 3 15.34 1 3 46.02ADXL330KCPZ 1 11.71 1 1 11.71MPX4115A-ND 1 12.45 1 1 12.45MSP1006-ND 5 2.4 1 5 12

Total 82.18

Sensors

Data Logger

RockSat 2008-2009

• RockSat Payload Canister User Guide Compliance– Mass:

• Estimated use: 2.5lbs

• Allotted: 2.5lbs

– Volume:

• Estimated use: 5.75” x 5.75” x 2” (dependant on sensor mounting)

• Allotted: 9” x 2”

– Payload activation

• G-switch – no voltage running prior to launch. On launch, mechanical G-switches activate powering electronic systems.

– Rocket Interface

• Complies with no-volt shorting wire setup.

Logistics

• Unable to meet with other schools before today– Have been in contact and all schools have agreed to the

standard mounting hole pattern.

• Latest email mentioned an additional payload

Team LeaderZach Glueckert

Thermal Structural

Systems Engineer

Control Systems

Electrical Engineer Tim Schneider

Zach Glueckert

Software EngineerBrendan Sheridan

Christina WatanukiChris

Reed

Management

Conclusions:

Concerns Shared canister integration

How to mount three/four different payloads together Center of mass/volume with other schools Mass and volume constraints

Flight DynamicsSpin Rate of Rocket