Critical Design Review - CO Space Grantspacegrant.colorado.edu/COSGC_Projects/RockSat-X...
Transcript of Critical Design Review - CO Space Grantspacegrant.colorado.edu/COSGC_Projects/RockSat-X...
2013 CDR
WVU Rocketeers Critical Design Review
West Virginia University Alex Bouvy, Ben Kryger, Marc Gramlich
12-12-2012
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2013 CDR
CDR Presentation Outline
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• Section 1: Mission Overview • Section 2: Design Description • Section 3: Prototyping/Analysis • Section 4: Manufacturing Plan • Section 5: Testing Plan • Section 6: Risks • Section 7: User Guide Compliance • Section 8: Project Management Plan
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Mission Overview: Mission Statement
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• Mission statement: Develop a payload which will measure the following properties of the space environment (up to 160 km) during the RockSat-X flight.
– Plasma density/frequency – Magnetic field – Flight dynamics – Magnetic effects on ferrofluids in microgravity – Protect a picosatellite payload consisting of an IMU and magnetometer,
as well as a transceiver to transmit data back to earth.
• Goal: To measure and analyze data from the flight, and compare the results to known atmospheric models. To transmit data from the picosatellite to Earth.
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Mission Overview: Theory and Concepts
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• Plasma conditions continuously change in the ionosphere with altitude and time of day. At these given times, the plasma fields resonate at different frequencies. The experiment will compare the instantaneous plasma density and frequency distribution to current atmospheric models.
• Earth’s magnetic field decreases as a function of distance from the center of the earth. The magnetic field reflects and traps many charged particles. Measuring field intensity can yield information required to accurately model this phenomena.
• Comparison between these measurements and current models will show
if assumptions made in these models hold up to an extent that they can be accurately used in future atmospheric applications.
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Mission Overview: Theory and Concepts cont.
• Ferrofluids are liquids that respond to magnetic fields. They are typically composed of iron particles suspended in a solvent (usually oil based). In near zero g conditions, it becomes difficult to control how a liquid is oriented in a container. Assuring the fluid remains in a certain location is useful in fuel tanks experiencing zero gravity. The goal is to use an electromagnet in order to sustain the location of the fluid within it’s container.
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Mission Requirements: Mission Objectives
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• A payload shall be constructed from which measurements can be made and viable science data obtained.
• The power block designed shall distribute power to each and every subsystem, and each and every subsystem shall be powered on.
• The science data obtained should improve upon current data from previous projects.
• The full payload shall fit on a single RockSat-X deck.
• The system shall survive the vibration characteristics prescribed by the RockSat-X program.
2013 CDR
Mission Requirements: System Level Objectives: Flight Dynamics (FD)
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• A system shall be developed to measure the dynamics of the rocket flight, including acceleration, pitch, yaw, and roll.
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Mission Requirements: System Level Objectives: Ferrofluid Experiment (FFE)
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• A system shall be developed such that a ferrofluid in a closed container can be monitored via external camera.
• The containment vessel shall be designed/selected to prevent possible spills/leaks of the ferrofluid.
• The camera system implemented shall properly record video/take pictures on command.
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Mission Requirements: System Level Objectives: Radio Plasma Experiment (RPE)
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• A system shall be developed to measure the density of a low-energy plasma in the space environment.
• Both a MHz and GHz antenna shall be designed and implemented to properly transmit corresponding MHz and GHz waves.
• A functional Langmuir Probe shall be designed and implemented.
• The antennas and probe should be interfaced to the RockSat-X deck in such a manner as to provide for optimal conditions for measurements to be made.
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Mission Requirements: System Level Objectives: Picosatellite Experiment (PSE)
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• A picosatellite shall be developed to house a basic payload, as well as a transceiver to transmit telemetry.
• A transmission protocol shall be implemented to dictate transmission format.
• Transmissions will take place on the range of 433.05-434.79MHz. The exact frequency has not yet been allocated by the IARL.
• Power output of antenna at 500mW.
• Antenna will broadcast in intervals of 30 seconds, once per minute.
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Mission Requirements: Minimum Success Criteria
1. The payload shall conform to the requirements set forth in the RockSat-X User Guide
2. The system shall measure the density of a low-energy plasma throughout the flight at no less than 50Hz.
3. The system shall measure data from each and every inertial sensor throughout the flight at no less than 50Hz.
4. The system shall observe the effects of ferrofluids in the presence of an electromagnet intermittently throughout flight, accumulating no less than 2 total minutes of video footage.
5. Telemetry data shall be received from the picosatellite. 6. The system shall save high resolution data on a hard disk. 7. The system shall transmit acquired data through WFF-provided
telemetry for data assurance.
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Mission Overview: Expected Results: Plasma
• Expect at least one or two peaks: – Plasma frequency – Gyrofrequency – Other frequencies possible (upper-hybrid frequency)
• Gyrofrequency varies little with altitude, plasma frequency significantly:
0.00E+00
5.00E+05
1.00E+06
1.50E+06
2.00E+06
2.50E+06
3.00E+06
3.50E+06
4.00E+06
4.50E+06
0 20 40 60 80 100 120 140 160
Freq
uenc
y (H
z)
Altitude (km)
Frequency Variability
f_ce (Hz)
f_pe (Hz)
f_uh (Hz)
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• The observed magnetic field is expected to decay following an inverse cube law as a function of distance from the Earth.
• Note: Earth’s magnetosphere is dynamic and should not be overgeneralized by an
inverse cube law. However, considering an expected altitude maximum of 160 km, standard dipole magnetism models are expected.
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Mission Overview: Expected Results: Magnetic Field
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Mission Overview: Expected Results: Ferrofluid
• Under the influence of a magnetic field (7000 gauss), it is expected that the magnetic fluid remain oriented towards the electromagnet throughout the duration of the four scheduled measurement times during flight.
• Fluid sloshing should be reduced in comparison to the non-magnetic control fluid.
• The control fluid is expected to move freely in it’s container.
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h=0 km (T=0) Launch
h=160 km (T=200) Apogee Nose Cone Separation FFE Cycle 3
h=6.3 km (T=455) Chute deploys
h=0 km (T=15 min) Splashdown
RockSat-X 2013: Concept of Operations
h=54.3 km (T=346) Experiments Power Off h=52 km (T=29)
End of Malamute Burn
h=0 km (T=-3 min) All systems except FFE on,
begin data acquisition
FFE Cycle: ON 3 seconds T: in seconds
(T=15) FFE Cycle 1
(T=90) FFE Cycle 2
(T=250) FFE Cycle 4
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Changes Since PDR
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• Scope of PSE has been reduced. • Picosatellite will no longer be ejected. • Experiment will instead focus primarily on
testing of transmission system.
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Functional Block Diagram Picosatellite Experiment
uController System
Langmuir Experiment
Flight Dynamics
Radio Plasma Experiment
Ferrofluid Experiment
Wallops Power & Telemetry lines
GSE-‐1
GSE-‐2
TE-‐R
TE-‐NR1
TE-‐NR2
TE-‐NR3
ADC Lines 1-‐5
Asynchronous Line
Power Block
Langmuir Board
IMU
Z-‐Accelerometer
Magnetometer
uController
Picosatellite Payload
Langmuir Probe
SD Card
Power: Red
Digital Signal: Gold
Analog Signal: Olive
ADC Lines 1-‐8: Lavendar
JHU Lines: Black
RS-‐232 Line: Orange
RPE Board
MHz Antenna
5.7V
Transmitting Antenna
3.3V
28V
28V
28V
-‐5 to +5V Sweep
GHz Antenna
6.0V
3.3V
5.0V
5.0V 6.0V
Camera
Electromagnet
6.0V
6.0V
RBF
Plug
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Mechanical Design Elements
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• Give me a brief overview of your final mechanical design
• Mechanical drawings should be included • Solid models (labeled) with many views should
be included • Any stress/strain analysis? • Material choices?
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Mechanical Design Elements
• The payload will consist of two makrolon layers. – 1st layer: PCBs, Base for picosatellite and
electromagnet – 2nd layer: MHz antenna, radio module, FFE display
& camera, SMA wiring • FFE enclosure (not yet modeled) and PSE enclosure to
be constructed of Aluminum. • Bayer Makrolon 1260 Brief Specs:
– Polycarbonate – Melt: 320 C = 608 F – Breaking Stress: 55 Mpa
• No current Stress/ Strain Analysis 23
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De-Scopes and Off-Ramps
• Scope of PSE has already been reduced.
• Off-Ramps – FD experiment may be eliminated. – Scope of RPE may be reduced.
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Organizational Chart
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Project Manager Alex Bouvy
Systems Engineer Ben Kryger
Faculty Advisors Dimitris Vassiliadis
Marcus Fisher Sponsors WVSGC,
Dept. of Physics, Testing Partners ATK Aerospace
WVU CEMR
Safety Engineer Phil Tucker
RPE A. Bouvy (lead)
M. Gramlich
FFE B. Kryger (lead)
A. Bouvy
FD B. Kryger (lead)
A. Bouvy
Power Mgmt. M. Gramlich (lead)
A. Bouvy
Test Lead M. Gramlich
PSE A. Bouvy (lead)
B. Kryger
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Subsystem Design: Flight Dynamics (FD)
• Critical components: – Inertial Measurement Unit (IMU) – Magnetometer – Hi-Res Accelerometer – Hi-Res Gyroscope
• Approximate mass: .5 lb.
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Subsystem Design: Radio Plasma Experiment (RPE)
• Critical components: – Langmuir Probe – GHz Antenna – MHz Antenna
• Approximate Mass: 2 lb.
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Subsystem Design: Ferrofluid Experiment (FFE)
• Critical components: – HD Camera
• Prospective camera: GoPro HD Hero – Ferrofluid vessel – Potential full experiment enclosure depending on tested
durability. • Prevent leaks • Protect camera and vessels
• Approximate Mass: 1 lb. • Electrical configuration
– GoPro (included in FD PCB) – Backlit grid powered from Power PCB
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Subsystem Design: Picosatellite Ejection (PSE)
• Critical components: – Ejection cylinder – Payload (IMU/Magnetometer) – Transceiver
• Approximate Mass: 3 lb.
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Prototyping FFE
• Electromagnet: – Ver. 1.0, 1.1 – 250 turns – 10 cm length – 2.4V – 26, 22 gauge wire – 4A – ~13500 gauss
• Ferrofluid: – 2ml, 2g
• Prototyping goal: – To determine the minimum
magnetic force required to pull the ferrofluid.
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Prototyping FFE
• Electromagnet version 1.0 and 1.1 both are significantly more powerful than needed. Based on lab lift force results (maximum lift: 673g), the magnitude of the magnetic field can be reduced by at least half. A field of 7000 gauss should be enough to hold the fluid in place.
• The new challenge is to greatly reduce the power required to run the magnet. This can be achieved by adjusting the turn density.
• "↓0 = µμ(&/( )* , where μ is the permeability, n is the number
of turns, L is the length, and I is the current. Turn density = &/( • The next prototype will have 1000 turns over a length of 5 cm.
This will allow the electromagnet to run on 2V at 0.50A while producing a magnetic field of 10000-13000 gauss. Power requirements will be adjusted upon results.
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Detailed Mass Budget
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Mass Budget Subsystem Total Mass (lbf)
FD 0.2 RPE 1.5 LPE 0.5 PSE 1 FFE 1
Enclosures & InsulaGon 5 Plate 3.425 Ballast Weight/ BaMeries 2
Total out of 15 +-‐0.5 14.625
Over/Under Under (0.375)
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Wallops Interfacing: Power
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Power Connector-‐-‐Customer Side Pin Func>on 1 JHU 2 JHU 3 JHU 4 TE-‐3: AcGvated at T=0 5 JHU 6 JHU 7 JHU 8 JHU 9 GSE2: AcGvated at T=0 10 TE-‐4: AcGvated at T=0 11 TE-‐5: AcGvated at T=0 12 GND 13 GND 14 GND 15 GND
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Wallops Interfacing: Telemetry
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Telemetry Connector-‐-‐Customer Side Pin Func>on Pin Func>on
1 JHU 20 JHU 2 JHU 21 JHU 3 JHU 22 Parallel bit 1 (MSB) 4 JHU 23 Parallel bit 2 5 JHU 24 Parallel bit 3 6 RPE data 25 Parallel bit 4 7 RPE data 26 Parallel bit 5 8 RPE data 27 Parallel bit 6 9 RPE data 28 Parallel bit 7 10 RPE data 29 Parallel bit 8 (LSB) 11 JHU 30 Parallel Read Strobe 12 JHU 31 NC 13 JHU 32 RS-‐232 14 JHU 33 RS-‐232 GND 15 JHU 34 NC 16 JHU 35 NC 17 NC 36 GND 18 JHU 37 GND 19 JHU
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Mechanical Elements
• Manufactured – FFE display – Electromagnet – RPE/ LPE antenna mount – MHz, GHz antenna – FFE & Picosatellite enclosures
• Purchased – PCBs – Electrical components – GoPro camera
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Electrical Elements - Manufacturing
• All PCBs (4) need to be soldered with purchased components.
• MHz Antenna will need to be constructed in lab. (coil)
• GHz Antenna constructed and tuned. (patch antenna)
• Langmuir Probe constructed and tuned.
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Electrical Elements – Revisions/ Procurement
• All PCBs have flown on 2012 flight. • PCBs requiring revisions:
– FD • ADD control line to Power PCB for electromagnet
– Power • ADD relay line for electromagnet
• Anticipated revisions: 3 (Allowing max error & optimization) • Procurement:
– PCBs- Advanced Circuits – Electrical Components- Digikey – Magnet Wire- Radio Shack
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Software Elements
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• Control software for FD, RPE, camera controls complete.
• Software will be verified on legacy subsystems.
• Software will then be verified again upon completion of this years subsystems.
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System Level Testing: FD
• Board will be constructed and individual sensors tested as follows:
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Sensor Testing Plan
MagnetometerMagnetic field by latitude and longitude of the earth is known. Magnetic field magnitude for Morgantown is known. In the presence of no magnet,
the magnetometer reading should produce this.
AccelerometerBy moving the board around, increases/decreases in respective directions
for the accelerometer should be observed. Additionally, at rest the accelerometer should read 9.81 m/s^2
Hi-‐Res Accelerometer
Same as Accelerometer
Temperature Temperature taken with respect to a reference temperature.
GyroscopeSimilar to the approach with the accelerometer, changes in corresponding
xyz-‐directions should be observed when moving the sensor.
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System Level Testing: RPE
• RPE will be tested to verify MHz and GHz transmissions are being made. This will include oscilloscope testing as well as spectrum analysis.
• By placing conductive materials opposite the antennas, a varying received signal response can be observed.
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System Level Testing: PSE
• Picosatellite payload will be tested in the same fashion as FD sensors.
• Picosatellite transmission will be tested on the ground to verify transmissions are made and received.
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System Level Testing: Power System
• Upon completion, the output voltages and amperages of the power system simply should be measured in order to verify proper operation. By measuring these values, it can be ensured that our power system will provide the calculated values to other subsystems.
• Our power system can then be integrated to remaining subsystems to verify proper operation of subsystems from supplied power.
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Mechanical Testing
• Based on SolidWorks drawings and mass budget analysis, there is low risk of exceeding mass or volume constraints. FD, LPE, and RPE have all been previously constructed and tested. These subsystems will be implemented largely unchanged.
• New to the 2013 payload include PSE, FFE, and Antenna mount. – Need verification for mass, volume, vibration & load effects. – Tests include physically measuring mass and volume, lab shakedown, and
spin + vibration testing by ATK. • Mass and volume tests will be performed throughout
construction. • Full mission vibration and spin tests tentatively will be
performed mid-April.
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Electrical Testing
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• Testing will take place over the course of the Spring semester as subsystems are constructed.
• RBF Pin to be implemented between Wallops lines and payload power block.
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Software Testing
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• Legacy software will be used to test FD, RPE.
• Legacy software for camera control also exists.
• These tests will be implemented incrementally, upon completion of subsystems.
2013 PDR
Risk Analysis
• Mission Requirements: – RSK.1: The system does not survive the vibration
characteristics prescribed by the RockSat-X program. – RSK.2: During flight, the power block does not properly
operate and fails to provide power to the subsystems.
• System Requirements: FFE: – RSK.3: During flight, the containing vessel fails and
ferrofluid is leaked into the surrounding environment. – RSK.4: Upon testing the electromagnet to be implemented, it
is determined that too strong a magnetic field will be produced and will interfere with others’ payloads.
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2013 PDR
Risk Analysis
• System Requirements: RPE: – RSK.5: The antennas/probe are interfaced in such a manner
that meaningful data is not received.
• System Requirements: PSE: – RSK.6: It is determined that picosatellite radio transmissions
will interfere with WFF telemetry.
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2013 PDR
Risk Analysis: Risk 1
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Risk Title RSK.1: Critical Failure on Vibration Testing
Risk Statement The system does not survive the vibration characteristics prescribed by the RockSat-X program.
Context Statement The system will be submitted to vibration testing at ATK in April and WFF in June. It is possible that this vibration testing will cause critical failure in one or more of the components/subsystems.
Closure Criteria If the system experiences a critical failure, the team must re-evaluate designs and rebuild before launch.
Consequence Rationale Likelihood Rationale
2 Upon failure, the team will be forced to re-evaluate designs and rebuild failed systems. The team will have approximately 2 months to do this.
2 Because the system will be submitted to vibration testing (through ATK) before vibration testing at WFF, the team should be fully prepared for vibration testing.
Con
sequ
ence
RSK.1
Possibility
2013 PDR
Risk Analysis: Risk 2
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Risk Title RSK.2: Power Block Failure
Risk Statement During flight, the power block does not properly operate and fails to provide power to the subsystems.
Context Statement If the power block fails, no subsystems will receive power and will therefore not be active during flight.
Closure Criteria This is a realized risk. Thorough testing will be done prior to flight to ensure this mission critical element is in place.
Consequence Rationale Likelihood Rationale
4 If no systems power on, this means that no data will be obtained and minimum success criteria will not be met.
1 This is unlikely to happen. The power block will be thoroughly tested prior to integration.
Con
sequ
ence
RSK.2
Possibility
2013 PDR
Risk Analysis: Risk 3
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Risk Title RSK.3: Ferrofluid Containment Failure
Risk Statement During flight, the containing vessel fails and ferrofluid is leaked into the surrounding environment.
Context Statement The ferrofluid must be contained in a sealed vessel. It is possible that vessel will break, and the ferrofluid will leak out.
Closure Criteria The vessel must be thoroughly tested before flight to mitigate risk of leaks.
Consequence Rationale Likelihood Rationale
3 If the ferrofluid spills and contacts other system components, it could cause a critical failure to the subsystem.
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As in the case of the power block , this is another component that will be thoroughly tested before flight. It will be submitted to both vibrations and thermal testing at ATK, and then vibrations testing again at WFF.
Con
sequ
ence
RSK.3
Possibility
2013 PDR
Risk Analysis: Risk 4
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Risk Title RSK.4: Electromagnet Too Strong
Risk Statement Upon testing the electromagnet to be implemented, it is determined that too strong a magnetic field will be produced and will interfere with others’ payloads.
Context Statement It is possible that, upon measuring the magnitude of the magnetic field output from the electromagnet, the field will be deemed too strong to use as it may cause interference with ours and other payloads.
Closure Criteria If the magnetic field is deemed too strong, the experiment may be removed.
Consequence Rationale Likelihood Rationale
2 The discovery of unmitigable interference may result in the removal of the subsystem. 3
It is known that the electromagnet will produce a considerably strong field. It is very possible that it will be discovered that this field interferes with other payload subsystems.
Con
sequ
ence
RSK.4
Possibility
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Risk Analysis: Risk 5
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Risk Title RSK.5: Antenna/Probe Misplacement
Risk Statement The antennas/probe are interfaced in such a manner that meaningful data is not received.
Context Statement
If the Langmuir probe is placed too close to the center of the payload, it may not interact with the space environment in an ideal manner. Additionally, if the GHz antenna is placed in such a manner that interference will be produced, its results may also be clouded.
Closure Criteria The payload subsystems should be laid out such a manner that the probes are placed in ideal positions.
Consequence Rationale Likelihood Rationale
3 If the probes are not placed correctly, valid science data may not be received from the subsystem.
2 It most likely that placing the probe/antenna near the edge will result in acceptable readings, providing valid science data/
Con
sequ
ence
RSK.5
Possibility
2013 PDR
Risk Analysis: Risk 6
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Risk Title RSK.8: PSE Telemetry Interference
Risk Statement It is determined that picosatellite radio transmissions will interfere with WFF telemetry.
Context Statement It is possible that WFF will determine that transmissions on the 435MHz band will interfere will WFF telemetry and will not be permitted.
Closure Criteria In this case, satellite telemetry will likely be removed from the subsystem, and the measurements stored on a hard disk.
Consequence Rationale Likelihood Rationale
2 Again, in the case of this, the subsystem must be redesigned. 3
It is considerably possible that the transmissions will interfere, as this is a common RF band used for telemetry.
Con
sequ
ence
RSK.8
Possibility
2013 CDR
User Guide Compliance
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Requirement Status/Reason (if needed) Center of gravity in 1" plane of
plate? Yes
Max Height < 12" Max Height <5.5”
Within Keep-‐Out Yes
Using < 10 A/D Lines 5 ADC Lines UGlized
Using/Understand Parallel Line Not Currently UGlized
Using/Understand Asynchronous Line 9600 Baud
Using X GSE Line(s) 1 (per requirement)
Using X Redundant Power Lines 1 (per requirement)
Using X Non-‐Redundant Power Lines 2 (one extra)
Using < 1 Ah .26 Ah
Using <= 28 V Yes
2013 CDR
Sharing Logistics
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• Johns Hopkins University – Measure electron density using a dual frequency GPS as
well as observe effects on an aerogel container. • Plan for collaboration
– JHU team members have opened an online forum. Here messages are exchanged with records kept of all conversations.
– Solidworks models will be shared. Teams may meet in person to verify fit checks.
• Structural interface – Payloads will be joined by aluminum standoffs.
• POC: Marie Hepfer: [email protected]
2013 CDR
Schedule
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12-Nov 1-Jan 20-Feb 11-Apr 31-May 20-Jul
Critical Design Review
FD Development
FFE Development
RPE Development
Power Block Development
Individual Subsystem Testing Report
Subsystem Integration
Payload Subsystem and Integration Report
DITL Test Report 1
DITL Test Report 2
Integration Readiness Review
Launch Readiness Review
2013 CDR
Budget
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Subsystem Cost ($) Total Budget ($)
FD 1000FFE 200
RPE 250 System Costs ($)
PSE 100 1750
Power Block 200
Total Costs($)Travel 1200 16950Earnest Deposit
2000PAID
1st Installment
6000PENDING
2nd Installment
6000PENDING
2013 CDR
Team Availability Matrix
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Monday TuesdayWednesdayThursday Friday7:00 AM Yes Yes Yes Yes Yes8:00 AM Yes Yes Yes Yes Yes9:00 AM No No No10:00 AM No No No11:00 AM No No No No No12:00 PM No No No No No1:00 PM No Yes No No No2:00 PM No Yes No No No3:00 PM Yes Yes Yes Yes Yes4:00 PM No Yes No Yes No5:00 PM No Yes Yes Yes Yes6:00 PM No Yes No Yes Yes
WVU Rocketeers: Spring 2013 RS-‐X Team Availability Matrix (All times EST)
2013 CDR
Contact Matrix
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Role Name Phone Email Citizenship OK to Add to Mailing List?PM Alex Bouvy (304) 376-‐0770 [email protected] U.S. YesFaculty advisorDimitris Vassiliadis (304) 293-‐4920 [email protected]. Yes" " (202) 315-‐6976 [email protected] -‐ -‐Media/Web William Kryger (444) 878-‐5166 [email protected] U.S. YesTeam Member Marc Gramlich (304) 550-‐3462 [email protected] U.S. Yes
WVU RocketeersFall 2012 RS-‐X Contact Matrix