Conceptual Design Review RockSat-C 2013... · INTEGRATION TESTING PLAN Integration of components to payload ... Tests will be preformed at Mitchell by ... Damage to electronic components

December 3, 2012

Mitchell Community College

MCC Aerospace Engineering and Technology

CRITICAL DESIGN REVIEW ROCKSAT-C

ROCKSAT-C 2013 1

Critical Design Review – Pegasis ll Mission Statement Concept

Organizational Chart Expected Results

Theories and Concepts

Design Descriptions Requirements Mechanical

De-scopes & Off-Ramps Electrical

Software

Prototyping Analysis Power

Prototyping Interfacing

Mass

Manufacturing Mechanical Electrical

Software

ROCKSAT-C 2013 2

Testing

System Electrical

Mechanical Software

Risks Changes since CDR Critical

User-Guide Compliance

Table Logistics

Project Management

Schedule Budget

Work Breakdown Schedule

Conclusion

ROCKSAT-C 2013 3

Mission Overview

Presented By: Patrick Mencias-Lewis

PEGASIS II

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MISSION STATEMENT

Our goal is to power space-based instrumentation systems by passively generating energy from transducers of a proprietary design. Energy will be harvested from the rocket flight, solar rays, and other sources. This will be accomplished by building a more robust and simplistic payload using transducers with increased efficiency and improved design characteristics. Results may lower cost and power requirements for space science by reducing the weight of electrical components.

ROCKSAT-C 2013 5

ORGANIZATIONAL CHART

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THEORIES AND CONCEPTS

• Electromagnetic transducers will utilize

Faraday’s Law.

• Solar transducers will utilize Photoelectric

effect.

• Peltier coolers will use solar transducer to act

as a heat sink for microprocessors

• Piezoelectric effect

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CONCEPT OF OPERATIONS

Concept of Operations

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CONCEPT OF OPERATIONS

• Event A

Ignition, spike in data, collection begins

• Event B

Orion burn ends, spike in data, collection continues

• Event C

Apogee, little to no voltage measured, collection continues

• Event D

Chute deploys, spike in data, collection continues

• Event E

Splash down, spike in data, collection continues until retrieval

RockSat-C 2013 9 ROCKSAT-C 2013 9

EXPECTED RESULTS

CONTROL

A sensing board will be powered by a fixed battery. It will

record and save data of different environmental variables.

EXPERIMENT

A sensing board will be powered by energy gathering

devices. The energy used from both sensing boards will be

recorded and saved for comparison. Energy produced by

transducers will also be recorded and saved.

TRANSDUCERS

Transducers are expected to produce from 2V to 15V peak.

Currents will vary depending on transducer design and coil

development.

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Mechanical Description

Presented By: Joseph Edwards

PEGASIS II

ROCKSAT-C 2013 11

• All transducers are to be completed as

designed.

• May implement a fractal design coil to

harvest the earth’s electromagnetic field.

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De-Scopes & Off Ramps

MECHANICAL DESIGN DESCRIPTION

Jerk

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Bristol

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EM Pendulum’s Pendulum

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EM Pendulum’s Base


Diving Board

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Aubade

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Electrical Description

Presented By: Tony Briceno

PEGASIS II

ROCKSAT-C 2013 19

ELECTRICAL DESIGN DESCRIPTION

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To be Completed

• Design and test a z-axis g-switch to latch power on after lift-off

• Test battery configurations for longevity and current supply

• Research availability of surface mount versions of components from

2012 mission

Changes

• Main processor and both sensing boards will contained on one circuit

board

• Low power processors were chosen for testing. No negative effects are

indicated from datasheets on processor performance. The lower

voltages will increase battery performance.

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Activation

• Our payload will use command line activation

• A z-axis g-switch will latch the power supply after lift off.

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Plan of attack deadlines

• 12/14 - Test different processors to confirm final selection

• 1/11 – Confirm components for power supply and basic processor operation

• 1/18 – Basic coil design testing should be done to determine possible voltage maximums

• 1/25 – Confirm components for USB operation to comply with USB 2.0 standards

• 2/8 – Build proto-board to test revision 1 of software code on

• 2/15 – Final coil designs should be determined for each transducer

• 2/22 – Finalize revision 1 of board design and expand to include sensing boards

• 2/29 – Finalize voltage regulation of transducers to keep from damaging processors during A/D conversion.


To be considered

• Voltage regulators need to be chosen for each processor, 2 in total

• At least 3 revisions will be needed before a flight ready board will be

available

• 2 prototypes will be built in house for testing. Revisions 1 and 2.

• Subsequent revisions will be designed for manufacture from a board

house.

• PCB to transducer wiring harness connectors and wiring still needs to be

determined

• Smaller more efficient solar cells need to be obtained to replace the

current Aubade design

Software Description

Presented By: Tony Briceno

PEGASIS II

ROCKSAT-C 2013 26

SOFTWARE DESIGN DESCRIPTION

Purpose

• Control the measuring of power developed by transducers and used by

sensing boards

• Store the information in a readable form.

I/O’s

• Analog input for transducers and sensing boards (ADC)

• Digital output for indicator LED

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To be Completed

• Processor settings need to be confirmed and tested for proper

operation.

• ADCloop – Settings need to be checked and code tested to check

proper operation.

• USB settings need to be confirmed. Preferably compliant with USB 2.0

standards. Interface and code needs to be checked for proper

operation.

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Pseudo Code

Main

{

Start Infinite loop

Initialize (); Setup the processor

CntDwnWait (); Wait until < T-1min

SBactivation (); Send signal to start ADC cycle for both Sensing

Boards

Start ADC infinite loop

ADCloop ();

}


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Pseudo Code

Initialize

{

Select clock settings

Select Communication ports and settings

Select analog ins and digital outs

Set interrupts

}

CtnDownWait

{

Loop for Aprox 2 min

}


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Pseudo Code

SBactivation

{

Set two outputs to low -this signals the SBs to start the ADC cycle

}

ADCloop

{

Select AD channel

Transmit AD channel to SDcard

Capture AD voltage

Transmit AD voltage to SDcard

If all channels have not been sampled repeat loop

If all channels have been sampled, send newline command to SDcard

Repeat loop

}


Plan of attack deadlines

• 12/14 - Test different processors to confirm final selection

• 12/21 – Confirm working code for processor initialization is working

• Holiday break – use to time research USB 2.0 standards

• 1/11 – Confirm A/D settings and ADCloop code functions properly

• 1/18 – Finalize and test activation sequence for sensing boards

• 1/25– Confirm USB settings and basic interface with computer

• 2/1– Improve interface with computer to allow streaming data when

connected

• 2/8 – Test all portions of code working as one

• 2/15 – Finalize revision 1 of software code

ROCKSAT-C 2013 34

Prototyping/Analysis

Presented By: Colin Robinson

PEGASIS II

ROCKSAT-C 2013 35

PROTOTYPING/ANALYSIS

We have yet to begin testing. We have been designing and

building our own equipment to test our components for each

subsystem. We have also begun breaking down PEGASIS l parts to

test against new components.

ROCKSAT-C 2013 36

PROTOTYPING/ANALYSIS

We are in the entry stages of prototyping and will have it complete by the beginning of next semester.

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MASS BUDGET

PEGASIS Mass Budget

Subsystem Total Mass (lb)

BSTL .26 (by hand)

EMPD .08

DVBD .18 (by hand)

JERK .35

CRSH .11

ABDE .02

ELVS .01

Total 1.01

Over/Under (including electrical &

hardware)

0.78


Power Budget

Subsystem Voltage(V) Current(A) Time On(Hrs) Amp-Hours

Main 3.3 0.15 1.25 0.1875

SBCon 3.3 0.15 1.25 0.1875

SBExp 0 0 0 0

Total(A*Hrs) 0.375

• Preliminary battery pack designs have us at approximately 7.5V and

9000mAh

• Maximum current draw of the processors combined is approximately

400mA. Even if the batteries drain twice as fast as rated, there will still be

sufficient current/voltage to power the devices for longer than planned.

Manufacturing Plan

Presented By: Mason Young

PEGASIS II

ROCKSAT-C 2013 40

MANUFACTURING PLAN

Need to be manufactured:

• Makrolon Plates

• Mounting Board for Electronics

• Mounting device to hold battery

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MANUFACTURING PLAN

Still need to be procured:

– All items will be manufactured in house

– Research on new magnets and possible

procurement

ROCKSAT-C 2013 42

MANUFACTURING PLAN Manufacturing Plan

(Some parts my be reused)

1/9: Flights Awarded

1/14: Jerk, Bristol, EM Pendulum, & Diving Board

1/21: Test 1 Shake table/ spin tests

1/28: Evaluate Tests and improve transducers

1/30: Online progress report 3 due

2/4: Test 2 Shake table/ spin tests

2/11: Re-evaluate Test data

2/15: Individual subsystem test due

ROCKSAT-C 2013 43

MANUFACTURING PLAN

Electrical elements

Need to be manufactured:

• 2 prototypes

• Proto-board

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Testing Plan

Presented By: Nathan Keller

PEGASIS II

ROCKSAT-C 2013 45

TESTING PLAN

• Tests will verify payload meets user guide

requirements and functionality under high G-forces,

strong vibrational forces, and heat

• Similar to last year a mock up payload will undergo

test flights and shake table testing

• Additional tests have been included to test

performance under heat and magnetic

interference

ROCKSAT-C 2013 46

TESTING PLAN

• Functionality of the payload and individual

components shall be tested through test flights and

shake table testing

• Measurement of G-forces and vibrational forces,

inspection of components, and results from

collected data will be used to verify functionality

ROCKSAT-C 2013 47

MECHANICAL TESTING PLAN

• Measurements of mass and volume will

verify payload remains within user guide

requirements

• Individual components will be tested on

fabrication is completed, full canister tests

will begin once all individual components

have been tested

ROCKSAT-C 2013 48

ELECTRICAL TESTING PLAN

• Electrical system will be tested to minimize

effects from magnetic interference, ensure

heat durability, and verify connections

between components can withstand flight

conditions

• Placement tests of components will be used

to minimize magnetic interference

ROCKSAT-C 2013 49

ELECTRICAL TESTING PLAN

• Connections will be tested during test flights

and shake table testing

• Payload will be tested for functionality under

heated conditions to verify durability.

• Electrical tests will begin once electrical

components are acquired

ROCKSAT-C 2013 50

SOFTWARE TESTING PLAN

It will be necessary to develop code to

measure output from transducers and

sensing boards during testing

Software testing will begin once A/d

converter is aquired

ROCKSAT-C 2013 51

INTEGRATION TESTING PLAN

Integration of components to payload (fit-

checks) will be tested once component

construction is completed

Tests will be preformed at Mitchell by

mechanical team

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Electrical connections to components will

be tested once components are

completed

Tests will be preformed at Mitchell by

electrical team

Integration of payload into canister tests will

begin once canister arrives


ROCKSAT-C 2013 53

Tests will be preformed by mechanical

team to confirm that components align

correctly with optical port

Integration with partner team will be

preformed at Wallops to ensure

compatibility between payloads and the

canister


ROCKSAT-C 2013 54


Tests will be preformed by designated

members from both teams

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Risks

Presented By: Nathan Keller

PEGASIS II

ROCKSAT-C 2013 56

RISKS

RockSat-C 2013 57

Highly Unlikely Unlikely Possible Likely

Negligible

Marginal PMF

Critical WMF MVF EGF

EWH PHD

Catastrophic RMF EGF - Damage to electronic components due to G-forces

EWH - Damage to external wiring harness PHD - Processor damage due to heat PMF - PCB mounting failure MVF - Mechanical mounting failure due to vibration

WMF - Wallops mechanical failure RMF - Rocket motor failure

RISKS

BigBiggest risks at PDR were:

Damage to external wiring harness

Processor damage dues to heat

Damage to electrical components due to G-

forces

These risks have been mitigated through selection

of parts and design of system, this will be verified through testing

RISKS

Highly Unlikely Unlikely Possible Likely

Negligible

Marginal PMF

Critical

WMF MVF EGF

EWH PHD

Catastrophic RMF EGF - Damage to electronic components due to G-forces

EWH - Damage to external wiring harness PHD - Processor damage due to heat PMF - PCB mounting failure MVF - Mechanical mounting failure due to vibration

WMF - Wallops mechanical failure RMF - Rocket motor failure

RISKS

Biggest risks presently are:

Damage to external wiring harness

Processor damage dues to heat

PCB mounting failure

Through testing of these components we plan to find possible flaws in design that can be addressed to mitigate risks

Rocket motor failure will have to be an accepted risk

User Guide Compliance

Presented By: Patrick Mencias-Lewis

PEGASIS II

ROCKSAT-C 2013 61

USER GUIDE COMPLIANCE

• The mass of the payload, including canister, is …( See Colin’s Slide)

• The center of mass of our canister is within the 1”x1”x1” envelope requirement, verified using SolidWorks.

• The payload control sensing board will be powered by a ______battery (ask Tony/See his Slides).

• Design of payload will utilize a 1.SYS.1 activation to ensure there is no

open connection of power from the transducers.

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SHARED CAN LOGISTICS

• We plan to share half a canister with New Jersey

• To communicate we plan to use Skype and email to share our designs

• To combine the two payload sections between us we plan to join using standoffs.

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Project Management Plan

Presented By: Catherine Maynard

PEGASIS II

ROCKSAT-C 2013 64

SCHEDULE

• Event Date

Testing Report Presentation Due 4/26/2013

Test report Teleconference 4/26/2013

Meeting 5/6/2013

Weekly Teleconference 4 5/8/2013

Meeting 5/13/2013


Meeting 5/20/2013



Launch Review Presentation 6/3/2013

Travel To Wallops 6/12/2013

Visual Inspections at and Integration at Wallops 6/13/2013

Presentation to Next Year’s RockSat Project 6/19/2013

Launch Day 6/20/2013

Event Date

CDR Teleconference 12/5/2012

Meeting 12/10/2012

Meeting 12/17/2012

Meeting 1/7/2013

Final Down Select 1/9/2013

Meeting 1/14/2013

Meeting 1/21/2013

First Payment Due 1/25/2013

Online Progress Report 1 Due 1/25/2013

Meeting 1/29/2013

Payload Subsystem Integration,

Teleconference for ISTR 4/1/2013

Final Payment Due 4/5/2013

Meeting 4/8/2013

RockSat Canister Sent to Customers 4/15/2013

Meeting 4/22/2013

BU

DG

ET

Description Date Subset Cost Total Cost

Canister 10/17/2012 Earnest Payment of $1000

1/25/2013 First Payment $3000

4/5/2013 Final Payment $3000

Total Canister Cost $7,000

Parts for Payload November Cost of parts $625

Makrolon Plate -$188

DC Motor For Testing -$120

Processors - $20

Elec. Components - $50

Other -$287

December Cost of parts $625

January Cost of parts$625

February Cost of parts $625

Total Parts for Payload Cost $2,500

Orangeburg Launch Trip 1 April

Date TBD Mileage $150

Motors $250

Total Trip 1 Cost $400

Food and registration cost for students at Wallops April $1,150

Orangeburg Launch Trip 2 May

Date TBD Mileage $150

Motors $250

Total Trip 2 Cost $400

Wallops Travel Cost June Van $800

June Fuel $400

June Hotel $3,500

June Facaulty Per Deium $500

Total Wallops Travel Cost $5,200

$16,650

WBS

Mechanical

• Jerk, Bristol, EM Pendulum, & Diving Board Manfacturing

•Construct prototype payload with working components

•Construct individual small payload section for individual component testing

Electrical

•Voltage regulators need to be chosen for each processor, 2 in total

•At least 3 revisions will be needed before a flight ready board will be available

•2 prototypes will be built in house for testing. Revisions 1 and 2.

•Subsequent revisions will be designed for manufacture from a board house.

•PCB to transducer wiring harness connectors and wiring still needs to be determined

•Smaller more efficient solar cells need to be obtained to replace the current Aubade design

Software

•Test different processors to confirm final selection

•Research USB 2.0 standards

•Confirm A/D settings and ADCloop code functions properly

•Finalize and test activation sequence for sensing boards

•Confirm USB settings and basic interface with computer

•Improve interface with computer to allow streaming data when connected

Management

•Voltage regulators need to be chosen for each processor, 2 in total

•At least 3 revisions will be needed before a flight ready board will be available

•2 prototypes will be built in house for testing. Revisions 1 and 2.

•Subsequent revisions will be designed for manufacture from a board house.

•PCB to transducer wiring harness connectors and wiring still needs to be determined

•Smaller more efficient solar cells need to be obtained to replace the current Aubade design

Work Break-Down Schedule

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PROJECT SUMMARY

• Remaining Issues: None.

• Areas of concern:

• 1.SYS.1 integration with systems that are always generating

electricity.

• Plan of Action

• After the final down selection we will begin construction of the Payload and testing of its components.

• Before winter break:

• BeginsSchematical manufacturing planning so after the final down selection we can begin manufacturing based on the plans constructed.

ROCKSAT-C 2013 68

Conclusion

Presented By: Catherine Maynard

PEGASIS II

ROCKSAT-C 2013 69

Conceptual Design Review RockSat-C 2013... · INTEGRATION TESTING PLAN Integration of components to payload ... Tests will be preformed at Mitchell by ... Damage to electronic components

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