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SPECTRE Manufacturing Status Review

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MSR Overview Customer:Advisor: Dr. Keats Wilkie Dr. Xinlin Li NASA LangleyDepartment of Aerospace Engineering Sciences, CU LASP SPECTRE MSR Project Overview Austin Schedule Austin Manufacturing Status: Hardware Conrad Manufacturing Status: Software Michael Budget Status Michael 2

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Heliogyro Background Experimental onboard spacecraft propulsion system Uses high aspect ratio blades that generate thrust from solar radiation pressure Blades are held in place by centripetal acceleration of spinning spacecraft bus Has advantages to traditional solar sails Blades can be pitched for more complex maneuvering No heavy support structures necessary 3

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Project Background No heliogyro system has ever been flown since first proposed in the 1970s NASA in interested in demonstrating the first heliogyro on a 6U CubeSat platform SPECTRE is designing a control system which will demonstrate the ability to 1 ) Pitch blades over a +/- 90 degree range relative to a satellite bus 2) Demonstrate the ability to augment damping flapping and pitching modes of the blade 2 Blade 6U CubeSat Design: Dimensions 10cm x 20cm x 30cm Housing Bus 4

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Blade Oscillations Blade Root Blade Tip Housing flap Nominal Blade Deflected Blade Flapping twist Blade Root Blade Tip Twisting 5

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FBD Blade HousingCubeSat Bus Power Supply MatLab User Interface Rotational Actuator Linear Actuator Camera LED Gumstix Arduino Due Actuator Drivers Mode, Angle, Rate (UART) Images Voltage RS232 instructions Angle, Logic (UART) Blade Linear Motion Pitching Motion Legend: -Power -Data -Commands -Motion 6 V 5 V 9 V >1 V 1.8 V 7

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Control Law block diagram cc + Derivative control PD- controller Actuator Plant Pendulum or Membrane ladder Plant Tip Deflection Camera Resolution Transport Delay - 8

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Control Law block diagram cc + Derivative control PD- controller Actuator Plant Pendulum or Membrane ladder Plant Tip Deflection Camera Resolution/ Measurement Error Transport Delay - Arduino Due/ User Interface Motor Drivers Heliogyro Blade Sensor (Camera) Image Processor 9

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Control Law Expected Performance Twisting Mode Flapping Mode 10

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Project Schedule

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Spring Break 12

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Spring Break All Machining Complete Controller Ready to be Tested 13

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SPECTRE Schedule Summary Team is currently 1-2 weeks ahead of schedule proposed at CDR Lead times shorter than anticipated for all parts Development of user interface started early Fully testable blade controller expected before spring break Will provided approximately 3 weeks of margin for the project Critical path of the project is now mainly dependent on software/electronics 3 weeks allocated for final interfacing of all controller boards 14

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Manufacturing Status: Hardware

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Design Modifications Increased blade spool length, reduced mass Larger Spool LengthSmaller Diameter Rolled BladeSmaller CubeSat Volume Blade Spool 15 cm Previous Design Linear Ball Bearing Shaft Mounts Linear Actuator 7.85 cm diameter 8 cm Sliding Carriage Carriage Guide Linear Actuator Camera 8.6 cm diameter 9 cm 17.5 cm 1.715 kg 1.550 kg 16

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Parts Purchased PartStatusExpected Delivery Linear Motor Driver In-RouteThursday 2/5 Rotary Servo- Motor In-RouteThursday 2/5 Rotary Motor Driver In-RouteThursday 2/5 ArduinoObtained Bevel GearNot Ordered2-3 day delivery Turntable Bearing Obtained Radial BearingNot Ordered2-3 day delivery Linear-Servo Motor In-RouteThursday 2/5 Linear Guide Rails/Carriage s Obtained Gumstix/Fire Storm Obtained CameraObtained Rear View Front View, Unspooled Blade Exploded Interface View, Unspooled Blade 17

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PartQuantity CubeSat Bus Walls4 Rotary Motor Mount1 Interface Walls2 Interface Mount1 Bevel Gear Modifications1 Blade Housing Walls4 Blade Spool Mounts2 Camera Mount1 Manufactured Parts Rear View Front View, Unspooled Blade Exploded Interface View, Unspooled Blade Bevel Gear Modification Bore Out 5/8 hole 18

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Manufacturing Tasks PartMachineCompletion Progress Estimated Time to complete Blade Housing wallsCNC, Knee Mill 4/40 hours Interface WallsCNC, Knee Mill 1/23 hours CubeSat Bus WallsCNC, Knee Mill 0/48 hours Blade Spool MountsKnee Mill/Lathe 1/22 hours Rotary Motor MountCNC, Knee Mill 0/12 hours Interface MountKnee Mill/Lathe 1/10 hours Bevel Gear ModsKnee Mill/Lathe 0/12 hours Camera MountCNC0/12 hours Remaining PartsEstimated Time to Completion 7/1519 hours ~ 1 -2 weeks 19

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Manufacturing Status: Software/Electronics Control Law/User Interface Image Processing Algorithm Camera Installation/Interface

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Software Overview 21

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Contol Software Overview User interface has been modified, the UI will use MatLab instead of LabView. MatLab interface much better with the Arduino Due The MatLab interface will recieve deflection angle data from the image processor board If the control law is active, MatLab will apply a derivative gain and send instructions to the divers The interface will also be able to send pitching commands to the motor drivers 22

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Arduino Interface Progress Arduino-Matlab Accessibility Role in Control System Connection through Arduino Programming USB Port Interface between Arduino and MatLab Serial Communication (Read/Write) via ASCII Send/Receive Data from Image Processor and Motor Drivers Identify/Test Digital I/O PinsProvide Power to LEDs Peripheral Read through SPI / I2CPossibly needed for communication with Image Processor PWM / Motor ControlPossible method of commanding actuators = Complete = Supported, but not tested yet 23

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Image Processing Algorithm Input: raw, uncompressed YCbCr image file Iterates through all pixels, applies a filter highlights those that belong to the markers Function finds the centroid of each marker separately, uses both centroids to calculate deflection angles Critical ElementStatus Compiles in C++Complete Runs on test imagesComplete Runs with data from Image Processing Camera Incomplete (need to interface camera with image processing board) Calibrate filter thresholdsIncomplete (need test images from camera) 24

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Camera Interface Status FirestormCOM-P Summit Expansion Board Wifi antenna Caspa VL 25

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Camera Interface Status Image Capture Started Made bootable micro SD Card Booted Firestorm with camera connected (power lights on everywhere) Attempted image capture commands -Failure to initiate image capture due to inability to parse pipeline links -Additional failure to use gstreamer native image capture function 26

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Camera Interface Work in Progress Image Capture Started Board has been successfully booted with 2 different versions of the operating system (embedded Linux), one older, one newer Problem with newer version: Modules not inserted need to re-compile kernel Problem with older version: Unknown if support is built in for Wifi (needed for installing necessary packages for Linux) Currently working on installing the older modules manually with the booting, downloading system (compiling kernel) 27

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Image Processor Status Summary Critical ElementStatus Image Processor Board BootsFinished Camera Connects, Receives PowerFinished Camera Driver is InstalledIn Progress Images CapturedIn Progress USB Connection with ArduinoNot Started (Potentially more difficult than camera interface) 28

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Budget

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Component:Number Needed: Lead Times (Weeks): Cost per Component: Total Price: Overo Firestorm-P13$159.00 Pinto13$ 27.50 Power Adapters23$ 10.00$ 20.00 Caspa VL13$ 75.00 Micro SD10$ 50.00 Arduino DUE16-8$ 50.00 USB Cable30$ 3.00$ 9.00 Linear Motor13$690.00 Linear Motor Driver18$226.00 Rotary Motor13$220.00 Rotary Motor Driver16-8$226.00 LEDs20$ 10.00 Aluminum Sheet11$ 50.00 Misc. Wires?0$100.00 Misc. Screws?0$100.00 Rotary Encoder13$ 50.00 Hardened Steel Shaft11$ 24.00 Linear Bearing with Pillow Block 11$ 40.00 Shaft Support21$ 44.00 Bevel Gear11$ 50.00 Turntable Bearing11$ 5.00 Radial Berings11$ 5.00 Precision Shaft (hollow)11$ 40.00 Mounting Components11$ 40.00 TOTAL$ 2300.50 Original Margin: $2699.50 Shipping Costs were originally included in margin (~$300) 30

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Component:Number Needed: Lead Times (Weeks): Cost per Component: Total Price: Overo Firestorm-P13$159.00 Pinto13$ 27.50 Power Adapters23$ 10.00$ 20.00 Caspa VL13$ 75.00 Micro SD10$ 50.00 Arduino DUE16-8$ 50.00 USB Cable30$ 3.00$ 9.00 Linear Motor13$690.00 Linear Motor Driver18$226.00 Rotary Motor13$220.00 Rotary Motor Driver16-8$226.00 LEDs20$ 10.00 Aluminum Sheet11$ 50.00 Misc. Wires?0$100.00 Misc. Screws?0$100.00 Rotary Encoder13$ 50.00 Hardened Steel Shaft11$ 24.00 Linear Bearing with Pillow Block 11$ 40.00 Shaft Support21$ 44.00 Bevel Gear11$ 50.00 Turntable Bearing11$ 5.00 Radial Berings11$ 5.00 Precision Shaft (hollow)11$ 40.00 Mounting Components11$ 40.00 TOTAL$ 269.00 Current Expenditures $2320.62 Estimated Final Expenditures $2589.62 Estimated Margin $2410.38 Margin is sufficient to repurchase any component multiple time if necessary 31

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Backup Slides

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Critical Project Elements Blade is kept in a housing that can accommodate a spooled blade of 500+ meters in length Blade housing has 1.4U volume, electronics require 0.4U in CubeSat bus Total of 1.8U System requires 20 W Total mass of a single blade+housing assembly ~1 kg. 33

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SPECTRE Work Plan Fall 2014 Spring Break Classes Start MSR TRR Spring Final Report Symposium Manufacturing Software Mechanical Electrical Systems 34

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Blade Controller Requirements Controller housing must be able to accommodate one blade capable of providing the spacecraft with a 0.1 mm/s^2 acceleration Controller must be able to pitch blades to 90 with 5 of accuracy Controller must be capable of sensing blade deflections without an ambient light source Controller and blade occupy 2U of volume (10cm x 10cm x 20cm) Controller must run on approximately 5 watts of power Controller must conform to Cubesat weight requirement ~1.3 kg/U, total of 2.6 kg 35

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Camera Interface Status Image Capture Started Tried using old u-boot image, kernel 2.6.34 instead of current 3.5.7, but it wouldnt boot Tried installing modules from 2.6.34, but it wouldnt boot Tried again with installing the modules, but it wouldnt allow downloads (tried again, but it wouldnt boot) Currently working on installing the 2.6.34 modules manually with the booting, downloading system (compiling kernel) 36

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Justin Slides

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Control Law implementation cc + Derivative control PD-controller Actuator Plant Pendulum or Membrane ladder Plant Tip Deflection Change resolution of cameras Transport Delay - Receive the Data on tip deflection from the Camera Calculate the rate the tip is deflecting Implement a derivative gain Export the moment need to damp the solar sail blade to the motors 38

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Control Law implementation cc + Derivative control PD-controller Actuator Plant Pendulum or Membrane ladder Plant Tip Deflection Change resolution of cameras Transport Delay - 39

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Camera implementation cc + Derivative control PD-controller Actuator Plant Pendulum or Membrane ladder Plant Tip Deflection Change resolution of cameras Transport Delay - Calculate the tip deflection in degrees Transport Delay is placed in model to compensate for computational delays Send Tip deflection to the control law c =0 40

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Camera implementation cc + Derivative control PD-controller Actuator Plant Pendulum or Membrane ladder Plant Tip Deflection Change resolution of cameras Transport Delay - c =0 41

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Work Still Left to be done: Actuators cc + Derivative control PD-controller Actuator Plant Pendulum or Membrane ladder Plant Tip Deflection Change resolution of cameras Transport Delay - Actuators will receive the desired movement to create a moment Output the desired moment onto the solar sail to damp the blade 42