Post on 23-Dec-2015
Mitchell Aerospace and Engineering Mitchell Community CollegeFebruary 13, 2011
Individual Subsystem Testing
Report
Mission OverviewMission Overview
Functional Block DiagramsFunctional Block Diagrams
Changes from CDRChanges from CDR
Project Management and Team UpdatesProject Management and Team Updates
Subsystem OverviewSubsystem Overview
Outline of Presentation Outline of Presentation
Lessons LearnedLessons Learned
ConclusionsConclusions
Mission OverviewNathan Keller
Mission OverviewMission OverviewGoal Statement:
Our goal is to design and implement various transducers to
passively collect energy for possible use for space based
instrumentation. We expect to harvest energy from the flight
of the rocket, solar and magnetic sources.
Mission OverviewMission Overview
Mission Requirements: For each transducer, voltage across a known resistor will
be measured and data will be stored.
○ Some transducers may require amplification of voltage.
The power used by a customized-in-house (CIH) sensing
package will be measured and stored.
Measurable data from the CIH sensing package will be
saved.
Expected ResultsExpected Results
Subsystem Overview- Block Subsystem Overview- Block DiagramDiagram
ArduinoMicrocontroller
Bristol
EMPendulum
DivingBoard
GrowHot
Crusher
Aubade
Elvis
Jerk
Openlog
CIH SensingBoard
7.2VBattery
OpenlogPower on fromWallops
Legend:
----- Power----- Data
----- Serial Data
Op Amp
Resistor
Subsystem Overview- Block Subsystem Overview- Block Diagram Diagram The signal from each transducer will travel through an op amp(if
necessary) and then a resistor of a known value.
The signal will then input into the Arduino where the voltage will be measured.
Upon receiving power-on from Wallops, the Arduino will begin tracking the time from power on to a predetermined stopping time.
The Arduino will also send a digital signal to the CIH board to bring it out of its idle state.
Both the Arduino and CIH sensing package will store data to an OpenLog data logger.
Changes from CDRMechanical
Gary Staggers
Mechanical Changes Mechanical Changes
Makrolon Plates & standoffs:
○ Increased the thickness of the plates.
Originally planned to use 1/8” plates, but modified to use 3/16” for added
strength.
○ 5/16” Aluminum Hex standoffs tapped to 8-32 have replaced
the original cylindrical standoffs.
Mechanical Changes Mechanical Changes
Transducer Changes:
Jerk
Changed tube ID from 3/4” to 5/8”.
Magnet size updated from 3/4” to 5/8”.
Changed springs from stainless steel to copper beryllium.
Changes were made to reduce weight, after testing reveals
the smaller size is just as effective.
Mechanical Changes Mechanical Changes
Transducer Changes:
EM Pendulum
Magnet lengthened to a 1 inch overall length mounted in
a ball joint mechanism.
Bowl design has been modified to 4 coils perpendicular to
the aluminum cylindrical base.
These changes were implemented because the original
design was not effective in producing voltage.
Mechanical Changes Mechanical Changes
Transducer Changes:
Bristol
Construction altered from aluminum to ABS plastic.
Magnet is a spherical 5/8” neodymium magnet.
These changes were implemented to accommodate the 3-D
printer at the college.
Mechanical Changes Mechanical Changes
Transducer Changes:
Aubade
Dimensions have been adjusted to fit comfortably on the
second shelf facing the optical port.
Mechanical Changes Mechanical Changes
Transducer Changes:
Crusher
Crusher has been downsized since CDR, due to
considerations of weight, cost and space.
Originally Crusher was designed to be 1” x 1” x 1.5”, and
the current design is 2” x 2” x 0.2”. This reduced volume
from 1.5 cubic inches to 0.8 cubic inches, which results in
a proportional decrease in weight and cost of production.
Mechanical Changes Mechanical Changes
Transducer Changes:
Elvis
Still in development.
Current condenser needs further testing to prove its
viability for the project.
Mechanical Changes Mechanical Changes
Transducer Changes:
Diving Board
The cantilever has been changed from aluminum to
Lexan.
Tensile yield strength of Lexan is higher than 6061
aluminum.
Maximum yield strength of Lexan is 65.8 Mpa, 9543 PSI.
Maximum yield strength of 6061 Aluminum is 55.2 Mpa,
8007 PSI.
Mechanical Changes Mechanical Changes
Transducer Changes:
Grow Hot
No changes since CDR.
Changes from CDRElectrical/Software
Dylan Stobbe
Electrical Changes Electrical Changes
The I2C (inter-integrated circuit), the main protocol for
communications between the two microcontrollers, is no
longer necessary.
The second Arduino Microcontroller has been removed.
The main Arduino will control the power to the CIH
sensing board.
Further testing needs to be done to see which
transducers need rectification; Crusher, Aubade, Elvis
and GrowHot do not need rectification.
Electrical Changes Electrical Changes Sensing Package:
The scope of the project has been broadened somewhat
by the switch from an OTS sensing package to a CIH
option.
The CIH package will represent the power consumption
of a comparable.
In addition to serving as a power comparison, the sensing
board will provide useful data regarding the flight profile of
the rocket.
Changes from CDRTest
Erin Wilson
Test Changes Test Changes
No changes since CDR
Changes from CDRSafetyErin Wilson
Safety Updates Safety Updates
Safety presentation given followed by a written test.
All students passed with an 80% or better.
Project Management Update
Beau Brinkley
Team PhotoTeam Photo
Back Row (left to right): Brad, Dylan, Colin, Tony, Joseph, JohnFront Row (left to right): Doug Knight, Gary, Erin, Michael, Nathan, Clint Halsted
Project ManagementProject Management
Organizational Chart
Dr. DougKnight
Gary StaggersMechanicalManager
Erin WilsonSafety Officer
Beau BrinkleyProject Manager
Dylan StobbeElectrical Manager/
Director ofCommunications and
Translation
JohnBenfield
Test Lead
BradHager
MichaelBrown
JosephEdwards
TonyBriceno
CorbinTwitchell
Nathan'Krinkle'Keller
ColinRobinson
Clint Halsted
Project ManagementProject Management
Schedule Update Currently on schedule with only a few internal work task changes.
Some of the test components arrived behind schedule therefore,
manufacturing plan detail revisions have been affected.
In effort to meet schedule demands, Test data will be implemented directly
into design revisions rather than formally revising the manufacturing plan.
Subsystem OverviewBrad Hager
SubsystemsSubsystems Jerk
EM Pendulum
Bristol
Aubade
Elvis
Diving Board
Grow Hot
Sensing Board
JerkJerk
Winding wire around Jerk.
Brad
Jerk
Lathe
Winding the Wire
JerkJerk
Colin
Turning an End Cap
JerkJerk
JerkJerk
Status:
Prototype completed and flight tested.
Based on flight results, design will be updated to maximize
potential output.
EM Pendulum EM Pendulum
EM PendulumEM Pendulum
Status:
Prototyping dependent on delivery of final materials.
BristolBristol
Threaded Rods
Housing
Magnet
Enameled Copper Wire 30 AWG
BristolBristol
BristolBristol
Status:
Prototype is fully assembled.
Ready for a prototyping rocket flight with fully functional fin
tabs that will simulate rotation.
AubadeAubade
AubadeAubade
Status:
During the test flight in broad daylight, 6.70 V were
achieved.
The solar cells are mounted in Lexan sheet.
CrusherCrusher
CrusherCrusher
Status:
Testing will be completed this week.
Prototype is complete.
ElvisElvis
ElvisElvis
Status:
Testing to be completed.
Changes are anticipated moving forward but test results will
dictate route taken.
Biasing of the condenser mic may not follow our pathway of
passive energy harvesting.
Diving BoardDiving Board
Gary
Milling Diving Board Pieces
Diving BoardDiving Board
Diving BoardDiving Board
Diving Board Test Diving Board Test ResultsResults
Grow HotGrow Hot
Grow HotGrow Hot
Status:
Off the shelf, thermoelectric cooler.
Bench testing started.
Plan for Subsystem Plan for Subsystem IntegrationIntegration
Plan for Subsystem Plan for Subsystem IntegrationIntegration
Plan for Subsystem Plan for Subsystem IntegrationIntegration Make and finalize the physical layout of all transducers.
Place transducers on Makrolon plates and conform to center of
gravity specs.
Optimize wiring layout and pathways.
Change transducer placement as needed within the center of
gravity constraints and New Jersey’s center of gravity
requirements.
Sensing Board Preliminary Sensing Board Preliminary LayoutsLayouts
Bottom of Sensing Board Top of Sensing Board
Sensing Board Preliminary Sensing Board Preliminary LayoutsLayouts
Test RocketJoseph Edwards
Prototyping Test Rocket Prototyping Test Rocket
Joseph, Clint Halsted, Colin, Doug Knight, Tony, Corbin, Gary, Dylan
Construction of Payload Construction of Payload
Joseph
Corbin & Dylan
Dylan
Prelaunch: Rocket assembled in physics lab.
Completed Rocket Completed Rocket
Launch DayLaunch Day
Weather: cloudy, mist
Temp- 43 degrees F
Date:Feb. 10th 2:50 pm- arrived at launch site
Launch Launch
Corbin, Colin, Clint Halsted
Gary, Doug Knight, Colin, Joseph
Jerk
• Weighed Rocket.
• Began prepping rocket, motor, and nosecone.
• Turned payload on and started timer for payload exit program. T- 24 minutes to datalogging.
Launch Launch
Jerk
• Rocket taken apart to ensure correct packing of parachute.
• The rocket is angled slightly into the wind to correct trajectory.
• Ematch inserted into motor.
• Group backs up 100 feet from launch pad.
Launch Launch
Gary & Dylan Recording Flight Data
Recovery
Rocket Launch Test 1Rocket Launch Test 1
Update
4-inch test rocket launched on 02-10-12.
All systems tested (Jerk transducer, data logger and
microcontroller) functioned and contributed to a successful
launch.
Launch ResultsLaunch Results• A snapshot of the output from the first rocket testing of jerk.
• The time (in milliseconds), the integer values of each transducer, the time (in minutes and seconds), and the values in terms of voltage can be seen.
• The graph shows the transduced voltage vs. time.
Time
Vol
ts
SoftwareSoftwareProgram ran on the first flight of thePrototyping Rocket on 2-10-12
SoftwareSoftware
Update
While some previous versions of the software have been more
functional, some iterations have been buggy and produced
unpredictable results.
It was necessary to ensure the reliability of the software for the
test rocket and therefore a simpler version of the planned
software was produced.
Lessons LearnedDylan Stobbe
Lessons LearnedLessons LearnedMechanical
• Always have multiple lines of communication within the group.
• The first try will not produce the precise and polished result needed, so planning for several trials with each project is the best route.
• Quality is better than quantity.
• Always ask questions when unsure and seek out those who are experts on the topic.
Lessons LearnedLessons LearnedElectrical/Software
It is more important to have a functional program than a
fancy one.
If you need it to work, stick to the basics.
What works on the ground isn’t necessarily true during
flight.
Cable management is key.
Lessons LearnedLessons LearnedTest
• Always expect something to go wrong, so always allow more time than needed to make changes.
• Plan ahead with check lists and weather conditions before all test flights.
• Use modular designs and Autodesk software to improve the payload.
• Multiple techniques and Autodesk software are needed to create an accurate mass budget of the payload.
Lessons LearnedLessons LearnedTest
Original Payload Payload Revision
ConclusionsNathan Keller
Conclusion Conclusion
• All transducers have been designed; they are in the testing phase except for EM Pendulum.
• Programs have been tested and proved flight worthy and reliable.
• CIH sensing board is on schedule and viable.
• Mass requirements are proving not to be an issue.
• Project is currently on schedule.
• No foreseeable roadblocks in the future.